quality metal additive manufacturing
TRANSCRIPT
Unclassified
Unclassified
Quality Metal Additive Manufacturing (QUALITY MADE)
EPE FY17-03
_____________________
Proposed Pillar: Enterprise Platform Enablers (EPE)
Primary POM-17 Gap: FY17-35: Naval Platform and Systems Operational Availability
Secondary POM-17 Gap: FY17-34: Naval Platform and Systems Total Ownership Cost
Distribution Statement D: Distribution authorized to the Department of Defense and
U.S. DoD contractors only; critical technology; December 2014. Other requests for this
document shall be referred to the Office of Naval Research, 875 N. Randolph Street,
Arlington, VA 22203-1995.
Destruction Notice – For unclassified, limited documents,
destroy by any method that will prevent disclosure of contents
or reconstruction of the document.
Billy Short – Code 30
EC Manager ONR Code
Operational Problem
Problem Description: Gap FY17-35 - 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 Secondary Gap - FY17-34 - 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.
• Common Issues Across all Platforms: • Ageing 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/Depots mission includes producing parts to improve maintenance efficiency. They need new technologies to enable the reliable and cost-effective production of low volume parts.
Priority Documentation:
• VADM Cullom’s interest in AM as a Navy Innovation and Disruptive Technology
• Naval Additive Manufacturing Technology Interchange Recommendations report
• NAVAIR AM IPT and NAVAIR AM Roadmap as key AM technology enabler
• Key flag-level program endorsements
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PROPOSED SOLUTION (U) The Technology:
• Integrated Computational Materials Engineering (ICME)
Design w/ Closed Loop Process Control
(U) Similar/Related Projects:
• ONR SBIRs, Direct Digital Manufacturing & Advanced ICME
• DARPA’s Open Manufacturing Program
(U) TRL: Current (FY15): 4, Projected at End (FY20) 6
(U) Major Goals/Schedule by Fiscal year:
• Process Controls by 2Q FY18
• ICME Model by 3Q-FY19
• S&T Product Transitions to COM FRC/NSWC, Demo Parts
Transition to PEO-A, PEO-LS, PMS-317 in 4Q-FY20.
BUSINESS CASE (U) Key Metrics:
• Increase Platform Availability by reducing part acquisition
time (Mean Logistics Delay Time) by 50% (T), 80% (O) for
low volume parts that are currently cast.
(U) Proposed Funding ($K):
FY17 FY18 FY19 FY20 Total
5,275 8,680 9,125 7,632 30,712
(U) Program of Record: COM FRC/NSWC (S&T Products);
AAV, UH-1Y, H-53K, LPD-17 (Parts Demo)
(U) Acquisition Sponsor: Mr. Balazs (NAVAIR/Logistics and
Industrial Ops), Mr. Perryman (PEO-A), Mr. Taylor (PEO-LS),
Mr. Droz (PMS 317)
(U) Resource Sponsor: Mr. Hull/DC CD&I; N98; N4
(U) Fleet/Force Advocate: CAPT Futcher/N41, Mr. Truba/I&L
(U) ONR Contact: Mr. Billy Short / ONR 30 / 703.696.0842 /
OPERATIONAL NEED
(U) Objective: Ability to enable reliable and cost-effective
production of additively manufactured metallic parts at Naval
maintenance depots to significantly increase operational
availability of applicable Naval systems and to reduce
sustainment costs/delays by manufacturing “on demand.”
(U) Value to Naval Warfighter:
• Improve air, ground and sea platform operational availability
by reducing supply chain delays; lower maintenance cost.
( ) Naval Input Source and Stoplight
(U) Primary Gap # & Title: FY17-35: Naval Platform and
Systems Operational Availability
(U) Impact if Not Addressed:
• Decreased Naval system operational availability
• High system total lifecycle costs to manufacture limited
production parts that are currently cast.
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(U) EPE-FY17-03: Quality Metal Additive Manufacturing
(QUALITY MADE)
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EC Relationship to Other S&T Investments
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• Transition’s DARPA’s Boeing’s tiFAB (titanium additive manufacturing)
• Leverage Penn State ARL’s Additive Manufacturing Demonstration Facility (also ONR performer)
DARPA Open Manufacturing
• Developing engineering models & design tools for titanium
• Relating key mechanical properties to processing parameters and chemical/metallurgical variables to the product
Builds from ONR Programs Advancing AM S&T
• M&S tools for digital design and manufacture for AM
• Closed-loop feedback control • Technique for rapid qualification
Willing to work with other countries that will open up their AM system architecture to allow integration of closed loop quality controls.
Program completes at end of FY16; TRL-5 for Ti process
Need an integrated program to TRL-6 for titanium, aluminum and steel
• Multiple discovery & invention programs • Small Business Innovation Research
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Products in the EC
Closed Loop
Process Controls
Start: TRL 4
End: TRL 6
Transition Part Design Using ICME
Models to NSWC/NAVAIR/Industry
Transition Process / Control Suite
to FRCs/Depots/Industry
M&S Tools: Integrated
Computational Materials
Engineering (ICME)
approach
ONR 33 ONR 35
Develop M&S and quality control tools & processes for 2 alloys (Ti-6Al-4V and Al-Mg-Si)
using 2 metal AM processes (T), 3 alloys to include the addition of steel (O)
Gap Level Metrics: (1) reducing part acquisition time from 8-28 months for low-volume production by 50%
(T)* & (2) reduce time/cost to design and optimize AM replacements for cast components by 30% (T).
Start: TRL 4
End: TRL 6
- Microstructure-Property Prediction
Capability as a function of process and
geometry: +/- 10% (T) and +/- 5% (O)
- Defects (T) match that of castings and (O) 25%
improvement
- Mechanical properties: (T) match that of castings
and (O) meet or exceed AMS
- Fatigue Properties: (T) match that of castings
and (O) match wrought
- Closed loop control process
capability: 2σ for tensile properties with
or 𝑃 ≥ 95%; (O) 3σ or 𝑃 ≥ 99.7%
- Uniformity of Microstructure (by %
volume): 90% (T) and 95% (O)
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Integrated Computational Materials Engineering
(ICME) Design w/ Closed Loop Process Control
EPE-FY17-03
Product Description: Modeling & simulation
tools to rapidly design, optimize & build AM
metallic parts. Process control tools to support
AM process fabrication & qualification. M&S
tools and process quality control sensors
developed, installed & demonstrated at Naval
centers/depots via fabrication of metallic parts.
Planned Demos/Transition
• Acquisition POR/Contact: COM FRC, AAV,
UH-1Y, H-53K, LPD-17; Mr. Balazs
(NAVAIR/Logistics and Industrial Operations),
Mr. Taylor (PEO-LS); Mr. Perryman (PEO-A);
Mr. Droz, PMS-317
• Resource Contact: Mr. Hull (CD&I); N98, N4
• Key Demonstrations (Qtr/Yr): Controls: 2Q-
FY18; Models 3Q-FY19; Parts 4Q-FY20
• Final Transition (Yr): 4Q-FY20
Warfighting Payoff: Enhancing the
quality and reliability of metal Additive
Manufacturing will: (1) increase
operational availability of Naval systems
and (2) decrease sustainment costs by
adopting AM processes for critical parts
that require low volume production runs
and where maintenance and cost
efficiencies are achieved.
TRL at Start: 4/5
TRL at Transition: 6
FY17 FY18 FY19 FY20 . Product Funding ($K) 5,275 8,680 9,125 7,632 Demos - Transition -
Distribution Statement D: Distribution authorized to the Department of
Defense and U.S. DoD contractors only; critical technology; 1 Dec 2014. Other
requests for this document shall be referred to the Office of Naval Research,
875 N. Randolph Street, Arlington, VA 22203-1995.
Destruction Notice – For unclassified, limited documents,
destroy by any method that will prevent disclosure of contents
or reconstruction of the document.
Unclassified
Unclassified
• ECPs for OP Test, Qual/Cert- AAV/LPD-17
• Flight Qual & Cert – UH-1Y / H-53K
• Develop initial ICME Framework & Evaluate
In-situ Sensors (Academia/Industry)
• ICME Model Development & Process Control
Optimization (Warfare Centers/FRC)
• ICME Model & Process Control Validation
(Warfare Centers/FRC)
• TRL 6 Parts Demonstration
Tests, Demos, Key Events, etc. FNC Product Transition
Demo Parts RDT&E
S&T Development
Path to the Fleet Integrated Computational Materials Engineering (ICME)
Design w/ Closed Loop Process Control FY17 FY18 FY19 FY20 FY21 FY22
Operations & Support
TRL 7 TRL 8/9
Part Op Test and Qual & Cert
Demo Part Transition: PEO(A): UH-1Y
PEO Land Systems: AAV
PMS 317: LPD-17
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TRL 6
Product Transition for TRL 6 Parts Demo:
NSWC / NAVAIR / FRCs
• Closed Loop Quality Control Integration at FRC/NSWC
• ICME Design Tools @ NSWC/NAVAIR
• Final S&T Transition of ICME and Process Control
Operations & Support
S&T Transition: Naval Surface/Air Warfare
Centers, Fleet Readiness Centers/Depots
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• Endorsements: Flag-level endorsements by Commander, Naval Air Systems Command; Deputy PEO ASWASM, Deputy Asst. Commander Logistics and Industrial Ops Naval Air System Command; PEO-Land Systems; OPNAV N41; other GS-15 endorsements: DC CD&I, DC I&L, & PEO-Ships
• Operational Need: PEO Land Systems, PEO ASWASM, PEO Ships portfolios consist of multiple platforms with rapidly aging assets currently in the Operations & Sustainment life-cycle stage that will require technology innovation to ensure platform operational availability; want AM to broadly support maintenance portfolios.
• Leveraged Programs: FNC is optimally aligned to transition and further develop multiple DARPA Open Manufacturing AM related efforts and multiple ONR SBIR & D&I related efforts.
• Timing: Supports DARPA tech transition at the end of FY16 for titanium AM processes and on the critical path of both Mid and Long Term NAVAIR AM Roadmap efforts. Aligned with purchase of Naval metallic AM capabilities across the Naval Surface and Air Warfare Centers and Fleet Readiness Centers and Depots. Supports CNO’s “Print the Fleet” initiative.
• Impact: Provides organic Naval maintenance capability to reduce mean logistics delay time for applicable parts, where AM is appropriate. Adds needed quality and reliability for metal AM.
• Cost Benefit: Reduces cost in AM design & optimization; reduces TOC, where applicable; saves money over point solutions
Summary Unclassified
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Backup Slides
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FNC Technology Bridges Gap to Enable Organic AM Production of Low Volume Metallic Replacement Parts
Technical base & FNC effort
Landing: FRCs, Warfare Centers, Depots, Industry
FNC Technology
• M&S tools to rapidly design, optimize &
build AM parts; support rapid qualification of
the AM process
• Quality control sensors & system
developed, installed & demonstrated via
fabrication of quality parts for PEOs
Transition & Tail
• Installation & demo of an organic Naval
maintenance capability to benefit Operational
Availability (AO) and TOC
• M&S tools & knowledge to speed
qualification & certification of AM processes
& parts; reduction of post-manufacturing part
inspection demands
• Tail is minimal: refine & introduce AM into
production plant, parts from TRL 6 to 9; pays
for itself through cost savings
Ensure quality of metal AM parts built by
Naval organic maintenance capabilities
by developing & instituting M&S tools and
quality controls during fabrication.
Naval capability to rapidly
qualify, certify AM processes
and fabricate quality AM parts Unclassified 10
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Commander
Naval Air System Command
“Using AM technologies in support of the Naval Aviation Warfighter is a top
priority for the command…NAVAIR strongly endorses.”
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DPEO (ASWASM)
PEO(A) will support the transition of “QUALITY MADE" products into the
platforms across our portfolio as the technologies are matured.
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Dep. Asst. Commander
Logistics and Industrial Ops
Naval Air System Command
“We will support transition of QUALITY MADE products into NAVAIR’s Fleet
Readiness Centers in support of aviation maintenance, repair, and overhaul.”
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Responsible for the
budget for FRC equipment
• ONR 30 (Short), 32 (Wardlaw), 33 (Mullins, Shifler, Perez, Hess), 35 (Pagett,
Nickerson) Technical program managers & supporting D&I/SBIR efforts
• PEO-Land Systems: Focus initial technology transition to PM AAAV (AAV)
• NAVAIR / PEO(A): AM research & technology transition to PEO(A) Platforms in
support of multiple aircraft (UH1Y, H-53K) & “across our portfolio”
• NAVSEA / PEO Ships: AM research & technology transition to LPD-17
• Marine Corps Combat Development Command (LID): POM planning, combat
development, Executive Agent for USMC S&T
• Deputy Commandant for Aviation; Deputy Commandant for Installation &
Logistics: Advocates for Aviation / Logistics requirements & policy
• OPNAV N4, N98: Responsible for Naval logistics & aviation programs; CNO’s
“Print the Fleet” Initiative; POM
• DARPA & NIST: Transitioning technology / knowledge to this EC
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Technology Base
Stakeholders & Team
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Academia &
Industry
QUALITY MADE Replacement Initiatives
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Unclassified
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AAV Transmission Housings Cast Al-> wire fed Al
• A key degrader of AAV readiness; fix to extend service life to
2030 when AAVs will be 51 years old on average
• Housings are warping and failing: vehicle weight increase,
need to reinforce jackscrew interface / damage during
maintenance
• MTBF unacceptable
• Expensive low volume castings with unacceptable Mean
Logistics Delay Time
• The complex geometry for the apex fitting limits the alternate
types of manufacturing permitted.
• Similar design exists on the AH-1W which has exhibited wear
damage historically. Repair options are limited due to the
internal boss as well as assembly requirements. UH-1Y Engine Mount Apex Fitting
• Complex castings prone to part quality deficiencies
• MTBF unacceptable / Corrosion issues
• Delays getting into work flow and unacceptable Mean
Logistics Delay Time
• Expensive low volume castings with very long part delays
Cast steel-> powder bed steel
H53K Cast Aluminum Gear Box
• Very Low Production Yield driving inventory cost and logistics
supply management oversight
Su
pp
ort
s N
AV
AIR
AM
IP
T R
oa
dm
ap
Ti -> powder bed Ti
LPD-17 Pump Impellers/Housing
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Additive Manufacturing Overview and NAVAIR Vision
Vision: Enable AM for our aviation and ship depots, DOD industrial base, and
end-users providing the capability to have qualified and certified critical
parts-on-demand
DLA/NAVICP/PMA “Stock the Data, Not the Part”
Manage Digital Warehouse, AM
Standards, Processes, Tools
DDM Notional Rapid Manufacturing Life Cycle
Problem Statement: “The Navy’s inventory of aircraft is being pressed into service beyond their
design life. As a result, components fail that were never expected to be repaired or replaced. With
no replacements available in the supply system, long lead times develop for the repair or
manufacture…..”
Broken / Unavailable
Part
Rapid Manufacture:
FRC, Industry, or Point of Use
Using AM Technology
Aircraft Ready for Tasking Parts on Demand
Identify Parts,
Develop Design,
Reverse Engineer
AM Computational Tool Framework
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Quality Metal Additive Manufacturing
(QUALITY MADE)
Unclassified
EPE-FY17-03: Quality Metal Additive Manufacturing (Quality
Made) Additive Manufacturing (AM) is a disruptive new
manufacturing process that will enable reliable & cost effective
low volume manufacturing to increase Fleet readiness when
appropriate. While early AM adoption is currently being used or
explored across the Naval Enterprise, technology development
is still necessary to realize AM's full potential for metallic
components, to improve designs, to reduce manufacturing
cost/waste, and to increase the quality and reliability of
manufactured parts. This EC will develop technologies that
provide a science based approach to AM design optimization
and process control and allow for increasing the size and
complexity limits of AM systems. These technologies will be
demonstrated to a TRL 6 by AM fabricating parts that are
currently cast and by rapidly manufacturing complex molds for
use in casting. Castings are a high value target for AM because
of their complexity, high initial investment cost and their wide
spread use across Naval platforms. The use of additive
manufacturing technology to manufacture metal “on demand
parts” can enhance operational readiness and reduce the total
ownership cost.
Associated Products FY17 FY18 FY19 FY20
Integrated Computational Materials Engineering (ICME)
Design w/ Closed Loop Process Control 5,275 8,680 9,125 7,632
EC Metrics:
Program Level:
- Increase platform availability by reducing part acquisition time (Mean
Logistics Delay Time) from 8-28 months for one-off parts, low-volume,
crash damage, and red stripe parts* by 50% (T) and 80% (O).
* 8-28 Month Baseline established by NAVAIR review of DLA data on multiple
aircraft for low volume production runs and out of production parts. Also
represents 50% reduction in part manufacture from 19-95 weeks.
- Reduce time/cost to design and optimize AM replacements for cast
components by 30% (T) and 50% (O). Eliminate need and cost for special
tooling/casts for applicable parts. Baseline is current cost/time to procure
cast parts.
S&T Product:
- Process capability 2σ for tensile properties with closed loop process
control [P (LSL ≤ x ≤ USL)≥95%]; (O) 3σ or ≥99.7%
- Microstructure-Property Prediction Capability as a function of process
and geometry: +/- 10% (T) and +/- 5% (O)
- ICME & processes developed for selected materials: 2 alloys - Ti-6Al-4V
and Al-Mg-Si using 2 metal AM processes (T), 3 alloys to include the
addition of Steel (O)
- Uniformity of Microstructure (by % volume): 90% (T) and 95% (O)
Demonstration Parts:
- Defects (Porosity, Lack of fusion) - Size and Number: (T) Match that of
Castings and (O) 25% Improvement over Castings
- Mechanical Properties: (T) Match that of castings and (O) Meet or
Exceed AMS for selected materials
- Fatigue Properties: (T) Match that of castings and (O) Match wrought for
selected materials
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Cost Estimate / Work Breakdown Structure
FY17 FY18 FY19 FY20 FY21
Task Performer FY17 FY18 FY19 FY20
System Engineering / Program Management $375K $315K $325K $332K
Refine ICME Framework for Metal AM (Ti-6Al-4V,
AlMgSi and/or Stainless 316L)
NSWC, NAWC
AD, & NRL $2,250K $550K
Process Control Sensor Development & Evaluation PSU-ARL $2,650K $500K
Experimental Process Model Development
(Processing-Structure-Property Relationships)
NSWC, NRL &
ARL $3,640K $1,350K
Process Control Optimization NAWC AD,
ARL, Industry $2,325 $1,250K
Model & Control Verification & Validation NAWC AD,
ARL, & NSWC $1,350K $4,200K $1,900K
Parts Demonstration (Ground, Sea, Air) NAWC AD &
NSWC $2,000K $5,400K
TOTAL $5,275K $8,680K $9,125K $7,632
Refine ICME Framework for Metal AM
Process Control Sensor Dev & Evaluation
Experimental Model Development
Process Control Optimization
Model & Control Verification & Validation
Parts Demonstrations (Ground, Sea, Air)
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Naval Benefits
• Dramatically improves current design process saving time and money
• Improved organic capability; provides confidence in AM for Naval
applications
• Resolves technical issues with designing complex geometries, larger
components, residual stress, and achieving desired volume and shape
• Understanding process & build history speeds later qualification
• Transitions technology & knowledge to FRCs, depots, and industry
• Shorten supply timelines
• Decrease cost for replacements
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Industry investments focused on mods, upgrades and derivatives.
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AM at FRCs Spring 2014 Exchange Meeting
Laser MDDM
Robotic MIG
Phase II SBIR (Keystone, Inc.)
Develop Closed-loop Control with
In-Situ Feedback Verification
Measure Z-Height & Melt Pool
Develop In-Process Bead Width
Sensor & NDE Methods
Phase II SBIR (Applied Optimization)
ICME Framework Development
Design substrate microstructure
Non-dimensional quantities of Porosity
(Marangoni), Wetting (Enthalpy ratio), and
cracking (Stress ratio)
Algorithm to control uniformity of
solidification
Modeling: CFD
Hat
ch w
idth
, m
Track size = f(process parameters)
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Quality Metal Additive Manufacturing SBIR Leveraging
Topic Number: N111-077: Rapid Part Qualification Methodology of Aircraft Metallic Components using DDM Technologies
Topic Number: N111-077: Rapid Part Qualification Methodology of Aircraft Metallic Components using DDM Technologies
ThermaViz Process Control Software Phase II.5 SBIR (Stratonics, Inc.)
Integrate thermal imaging sensor suite and
predictive thermal/metallurgical models to monitor
& control process
Verify desired microstructure and uniformity
Verify mechanical properties Layer
# o
f P
ixels
above
Te
mpera
ture
No Metric
Metric 1
Metric 2
Topic Number: N102-166: Direct Digital Manufacturing (DDM) of Metallic Components: Controlled Thermal Processing
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Strategic Risk:
• Risk in not exploiting this emerging tool; this is on the critical path for NAVAIR’s AM roadmap, FRCs/Depot need tools to exploit AM capabilities,& CNO’s “Print the Fleet”
Technical Risks & Mitigation:
• Incorporating process controls to closed machine architectures – Work with OEMs developing open architectures; NAMII efforts to open architecture
– Build upon success from ONR’s small business research efforts
• Risk in being able to develop accurate, fast-running models that closely approximate resulting AM material properties for different alloys
– Mitigate by building upon TRL-5 models for Ti-6Al-4V
– Conduct experimentation to anchor models; verification and validation
– FEA models optimized for AM that limit that optimize the mesh density, layer by layer, to reduce the computational burden (~20x faster); strategies to quiet/inactivate
– Can accept risk in speed if realized
• Risk in not achieving desired material properties – Post processing (e.g., HIP) to achieve homogenization,
remove voids, achieve full density, improve material properties
– Design of Experiments to refine and V&V models & reduce this risk
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ICME with Closed-Loop Process Control Risks
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Unclassified
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ICME with Closed-Loop Process Control Underlying Technology
ICME for AM: • Integrated computational materials
engineering (ICME) utilizes integration of computational processes to optimize materials, manufacturing processes, and design. Builds upon TRL 4/5 models at the end of DARPA’s OM program (end FY16).
• Emphasis on integration and engineering in order to shorten design, qualification, and certification cycles.
• Enables: ‒ Prediction of residual stress ‒ Choice of optimal build strategy
(energy, feed rate, path / hatch space) ‒ Prediction of resultant microstructure
Predict resultant material properties ‒ Assess part functionality ‒ Design the process to assist in rapid
qualification ‒ Quality by linking to closed loop
process controls
Process Modeling
During Design for
Engineering &
Economic Metrics
Coupled Thermo-
Mechanical Models for
Thermal History &
Stress State
Modeling Microstructural
Evolution during AM &
Post-Processing
Resultant Microstructures
and Phases on
Properties &
Characteristics
Material deposition
models, Lagrangian
energy source
movement, energy
flux
Finite element
analysis & material
property models
Thermodynamics,
atomic mobility &
phase
transformations
Assess functionality
Metrics:
• Reduce design & optimization by 30% (T) and 50% (O).
• Microstructure-Property Prediction Capability as a function
of process and geometry: +/- 10% (T) and +/- 5% (O)
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Process Control Technology
• Thermal sensors (TRL 6) and underlying process models will be at TRL 5 at EC start.
– Melt pool size/temp, cooling rates, part thermal history
– Will be adapted to AM alloys
– Evaluation and integration of other sensors (emission and hi-def camera) for voids & defects.
• Control software will close the process loop by monitoring thermal sensing data and perform statistical analysis of process performance model
– Thermal history & process parameters predicts resultant microstructure & property
– Predicts production reliability
– Adjust process controls to achieve desired performance
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ICME with Closed-Loop Process Control Underlying Technology
Metrics: • Process capability index (Cpk) reduction of uncertainty: (T) 2 sigma
for tensile properties with closed loop process control; (O) 3 sigma
• Stress-relieved, geometry-correct, defect free parts with desired
homogeneity as measured by uniformity of microstructure (% volume):
90% (T), 95% (O)
• Demonstration of the sensors and controls in a production relevant
environment (T).
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• FNC to utilize new AM capabilities at FRC SE, NSWC Indian Head, NAWC
Lakehurst, NUWC Keyport and other facilities as they come on line.
• This EC will leverage off of in-house expertise and organic depot level AM
capabilities to develop the technologies (60% in-house NRE / 40% University or
Industry): – NSWC Carderock, NAWC AD, and NRL to develop ICME Framework and perform initial
experimental model development
– ONR to leverage DARPA’s Manufacturing Demonstration Facility at Penn State Applied
Research Laboratory (ARL) to work on thermal sensor evaluation and process optimization.
– Install and validate in-situ sensors and closed-loop control process on AM equipment at Navy
Labs.
– Part Demonstrations for selected Air/Land/Ship components and materials to be done at FRC,
NSWC (or potentially a shipyard), and/or Penn State ARL.
• Key Cost Drivers: – Raw materials (Ti-6Al-4V, AlMgSi).
– Material studies to anchor models (V&V)
– Installation of thermal sensors at organic depot/lab – FY18
– Testing and evaluation (T&E) costs
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ICME with Closed-Loop Process Control S&T Procurement Approach