Quality Metal Additive Manufacturing (QUALITY MADE) EPE FY17-03 - - PowerPoint PPT Presentation

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Quality Metal Additive Manufacturing

(QUALITY MADE) EPE FY17-03

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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

• r 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 / billy.short@navy.mil

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

• r 𝑄 ≥ 95%; (O) 3σ or 𝑄 ≥ 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

• perational 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

• r reconstruction of the document.

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• 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;

• ther 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

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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

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11 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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12 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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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

Supports NAVAIR AM IPT Roadmap

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

• f 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

• wnership 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

Hatch width, 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 # of Pixels above Temperature 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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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
• rder 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
• f 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