Sponsor: US DEPARTMENT OF THE AIR FORCE THROUGH NATIONAL CENTER FOR DEFENSE MANUFACTURING AND MACHINING
W.M. Keck Center for 3-D Innovation
The additive manufacturing (AM) industry is changing quickly as users continue to push the limits of possibility. The success of producing an AM part typically depend on design guidelines that comprise several parameters, which can be categorized into three parameter types that include: 1) process related design parameters, 2) material parameters, and 3) individual machine parameters. Process related design parameters for additive manufacturing are fairly well understood between AM technologies, including feature size, surface roughness, minimum wall thickness, and more. Material parameters are also well defined per AM technology and include, as examples, powder size, size distribution, flowability, and packing density. Although design parameters and material parameters are generally defined according to a particular AM technology within a process category (Laser Powder Bed Fusion, Electron Beam Melting Powder Bed Fusion, Laser Directed Energy Deposition, etc.) machine parameters for Laser Powder Bed Fusion (LPBF) such as laser power, scan speed, gas flow speed, oxygen content, and layer thickness vary widely between machine types and between machine OEM's. The question that our national supply chain procurement personnel need to know is, "what guidelines should be followed to ensure a service bureau is ready and able to produce hypersonic components?". This proposal aims at developing a Hypersonics Material Readiness Program that aims to develop a design guideline specifically focused on machine parameters for Powder Bed Fusion (PBF) and Laser Directed Energy Deposition (L-DED). For this, the team will: 1) create an additive manufacturing design guideline specifically around machine parameters to best define the requirements needed to successfully produce components using Hypersonic-capable materials; 2) characterize the spectral emissive and temperature behavior of hypersonic materials to enable optimal and fact-based AM processing; and 3) leverage expertise developed at the Keck Center to support the design and manufacture of shape-stable leading edge hypersonic components.
Posting date: Wed, 07/10/2024
Award start date: Tue, 06/11/2024
Award end date: Thu, 06/11/2026