Quality Metal Additive Manufacturing (QUALITY MADE)

Enabling Capability

DISTRIBUTION A. Approved for public release: distribution unlimited.

Billy ShortLogistics Program Manager

QUALITY MADE EC ManagerExpeditionary Maneuver Warfare and

Combating Terrorism Departmentbilly.short@navy.mil

Unclassified28 July 2015

Operational Challenges

Naval Platform and Systems Operational Availability: Decreased platform availability due to an increasing number of part challenges that PMs are facing.① Challenges include very long Mean Logistics Delay Time for limited

production parts. ② Lack of commercial interest in low volume complex fabrication work and

significant delays in contracting and workflow.③ Increasing pressure on organic manufacturing capability. As an example,

Fleet Readiness Centers (FRCs) produce over 120,000 manufactured items per year.

④ Naval Platform and Systems Total Ownership Cost: High cost for limited production runs to make problem parts; many of those are cast components. This may also include large investments to create special tooling and complex castings.

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Operational Challenges

• Common Issues Across all Platforms:•Aging fleets with severe parts supply issues. Examples: Amphibious Assault

Vehicle will be 51 years old at the end of service life & aircraft will have 14,000 hours & designed for 6,000.

•Higher failure rates; new failure modes; exigent parts demand for critical components

•Systems down/deadlined for part obsolescence issues; decreasing vendor supply base

• Increase in components that fail that were never expected to be repaired or replaced

Stakeholders/Mission: Depots and FRCs are increasingly making parts to combat these challenges. FRC/Depot mission includes producing parts to improve maintenance efficiency. They need new technologies to enable the reliable and cost-effective production of low volume parts.

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AM Injection: Depot Level Maint.Supported by Warfare Centers

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① Early transition of ICME / digital design tools• Push upgrades• Support tooling before parts

② Installation of sensors on AM machines

③ Technical support to part demonstrations

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System Boundaries(Assumptions)

• Not addressing:– New AM machines; larger build volumes; faster

build rates– Performing qualification / certification– Cyber – Expeditionary use / shipboard integration

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Need to keep the system manageable

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FY17-20 Program Goals

• Enhance quality and reliability of metal additive while addressing key Naval issues – Build Naval confidence in material properties for critical

metal parts– Improved design and quality control tools & processes

• AM for Naval materials (Ti-64, AlMgSi, SS 316L casting analogs)

– Material properties better than cast and comparable to wrought• Achieve desired volume/geometry• Reduce residual stress• Improve fatigue properties

– Support speedy qual/cert 7

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FY17-20 Program Goals

• Improved AM design by gaining– From an enhanced understanding of the correlation of

materials properties to AM processes– Reduce required redesign iterations before an acceptable

design is achieved– Establish an upper and lower control limit for critical AM

process parameters for a successful build• In situ sensors and closed loop process controls to

ensure a quality build– Control AM process parameters to control microstructure,

volume, and geometry– Collect build data to support qual/cert

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EC Synopsis

Process-Structure-Property-Performance

Models

Quality Control

Start: TRL 4 End: TRL 6

Transition Models & Part Designs to NSWC/NAVAIR/Industry

Transition Process / Control Suite to FRCs/Depots/Industry

M&S and Design Tools

Sensors

Controls Casts

Start: TRL 4 End: TRL 6

Hardware & KnowledgeSoftware & Knowledge

Digital Designs& Hardware

(parts)

4 years, FY17-20

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Mr. Billy Short, ONR-30

Dr. Ignacio Perez, ONR-33Dr. William Mullins, ONR-33

Likely Acq Strategy; Defined in BAA(~2) Phase Is (for both ICME & QC), down-selecting to (1) Phase II

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ICME Overview

Process-Structure-Property-Performance

Models

Integrated Computational

Materials Engineering(ICME)

-----------------M&S & Design Tools

Software & Knowledge

• Model the AM process• Predict resulting

microstructure• Predict material properties

(stress, fatigue, etc.)• Predict part performance• Optimize build package • Accelerate process

acceptance

(T) Titanium, Aluminum, (O) Steel Alloy Casting Analogues for

2 different AM processes 10

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Interface to Closed Loop Controls

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Closed Loop Overview

• Thermal cameras & other in situ sensors

• Handoff from models– Upper and lower limits of

processes for a successful build

• Close the loop to control the build quality

Closed Loop Process Controls

Sensors

Hardware & Knowledge

• Heating rates• Peak temperature• Cooling rate • Melt pool dimensions &

solidification contour• Surface shape & roughness• Porosity

Titanium Microstructure

Control Algorithms

Sample Sensor Info

Microstructure and mechanical properties are determined by thermal history 11

Melt Pool Illustration

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Interface from ICME

Interface to AM Machine

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QUALITY MADE EC

• Fabricate quality part demonstrators with Air, Ground, and Sea communities

• PEO(A) (H-1 Helos)• PEO-Land Systems (PM AAA)• PEO Ships (LPD-17)

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• Challenges:– Defining the boundaries of the problems and sticking to it

(mission creep)– Open vs Closed AM architectures– ICME across a variety of AM processes and materials

• Self limiting to (2) processes and (2) threshold material (Al & Ti cast analogs with an option for stainless steel).

– Getting the physics right to inform the design and build at the optimal level of abstraction• Informed by the physics while maintaining computational efficiency,

where required– Integration / interface between ICME products and Closed Loop

Controls– Continuing to develop framework to support later rapid

qualification and certification in acquisition

Challenges

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• Provide us feedback! Ask questions. • Post all industry day briefs on registration website• https://

www.onlineregistrationcenter.com/register.asp?m=4269&c=113

• Open ONR website to allow communication to government and teaming

• Refine Broad Agency Announcement – White Papers– Downselect & seek full proposals– Final selection

• Initiate contracting actions (up to 12 months) • Program start 1 Oct 2016

Next Steps

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Backups

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System Architecture, Machine Interface and Management Algorithm

Validation Tests for Sensor Systems for In-

Process Tracking

Validation Tests for ICME/ Physics Based Tools

System of ICME/ Physics Based Tools

Sensor Systems for In-Process Tracking

Requirements for finished product quality and

properties

Integrated System Demonstration and

Validation

Validation and Verification Requirements

Closed Loop Control System

Validation Tests for Closed Loop Control

System

Acceptance Tests

Valid

ation

Design

Specifications, KPPs

Sensor Requirements

Processing Parameters Valid RangesMaterial Microstructure Requirements

Sensor Signals

Microstructure Verified

Part Properties Verified

All Requirements Verified

Architecture Selection Compatibility Verified