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Christian Désagulier, Materials & Processes Expert

An ALM Qualification Logic Proposal for Space Equipments

SIRRIS, Liege Science Park, Rue Bois Saint Jean 12, 4102 Seraing 2014, May the 13th

Current applications, trends and future developments of metal Additive Manufacturing / 3DPrinting for space and aviation

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Introduction : 3 ALM school cases..

Copper foil gilded for DGR telecom reflector antenna

Integral Co-curing for ULR Ku sandwich (1 ply per skin, without adhesive, < 1 kg/m2)

Launchers CFRP composite Tanks

Ti64 brackets EBMed for ULR Ka antenna reflector

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1st ALM case : Copper foil gilded for DGR antenna

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- 35 microns Copper foil annealed 1360 x 3500 mm- 0,5 micron gilded- NDI Gold thickness - Sample traveler for adhesion tests

more than 80’s flying since 1995 (i.e. 320 gilded copper foils)

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2d ALM case : Ultra-Light Reflector Ku antenna

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- Integral Co-curing : 1 ply per skin, without adhesive, sandwich < 1 kg/m2

- NDI (thermography, US) + curing cycle checking

- Mimic sample traveler (OOP/ Compression tests, micrographs)

100s customized antenna reflectors in flight since 2000..

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13 May 2014 7

The well known Additive Layer composite Manufacturing machines CFRP based

Filament winding

Tow placement

- Spherical tanks from Ø 0,3 m to 1 m

- Cylindral tanks & structures from Ø 3m up to 5,5m, H up to 12 m

3d ALM case : CFRP Launchers Composite tanks & structures

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13 May 2014 8

100’s ALM tanks on civil and defence launchers, manufactured since 25 years..

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3d ALM case : Satellite Bi-axial Sun Sensor

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3d ALM case : Satellite Bi-axial Sun Sensor

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Sirris, 2014, May the 13h

Telemetry Support (TMTC) + Bi-Axial Sun Sensor (BASS) Ti64 node support- Conventional design for back up need- Quality audit of the manufacturer subcontractor and registration of the qualified EBM process- Manufacturing according to registered process- NDT & traveler samples checking- Mast to CFRP tubes integration with bonding of the knot- Mast to Satellite integration

ATLANTIC BIRD 7, first ALM commercial application in GEO, launched on Tuesday the 27th of September 2011, delivered to the customer on the 23th of October..

3d ALM case : Satellite Bi-axial Sun Sensor

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ALM - One Technology But Several Processes

Powder Bed Wire feed

Ti64Inconel

Stainless steelsScalmalloy®

Maraging

Electron Beam

LASER

CMTTi64

Stainless steels

INVAR ?

CrCo alloys and High T° alloys

Al-Si-Mg Alloys

HP-Al Alloys(2xxx, 7xxx)

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General technical status@EADS

General technical status@AIRBUS

AIRBUS

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ASTRIUM Qualification logic

Two possible approaches

Proof load test on each new built part, or on one part per batch

Validation of samples produced with the parts

Traceability

NDI qualification

High level Incoming inspection

“Conventional”The long-term target

“Composite”Interim approach duringALM maturity development

the choice depend on the maturity of processes and considering volume of parts..

Development of a specific qualification logic, in particular on inspection and verification methods, contributing to increase of technical maturity

Impact and sensitivity of process parameters

NDI qualification

Raw material (powder) supply chain qualification

Confidential

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