N102-166 TITLE: Direct Digital Manufacturing (DDM) of Metallic Components: Controlled Thermal Processing

TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-265 (F/A-18 Program) and PMA-257 (AV-8B Program)

OBJECTIVE: Develop a controlled thermal process to produce a uniform microstructure, defect free and near net shape qualify metallic aircraft components using DDM.

DESCRIPTION: Direct Digital Manufacturing (DDM) of aircraft metallic components is an emerging and innovative manufacturing process which creates metallic parts directly from from powder metal. These metallic parts are intended to be used as the final product itself with minimal post-processing such as machining and surface finishing. DDM promises cost, time and efficiency benefits over traditional machining processes (in which material is removed using cutting tools) in the area of low production volumes, processes involving constant design iterations and manufacturing parts that have relatively complex geometric shapes. Additionally, as compared to traditional machining of metal parts, DDM technologies will allow engineers to create more efficient, creative, and innovative aerospace-related designs rapidly and accurately in which complex features and internal passages can be created that could not be created with traditional machining methodologies and techniques. Currently, available direct-metal additive manufacturing process lacks the level of process monitoring and control desirable for process certification efforts. The usage of thermal process monitoring ensures that the deposited material is neither too hot nor too cold. These high or low temperature conditions can lead to defects resulting from either lack of fusion between layers if low processing temperature or excessive vaporization of alloying elements if high processing temperature. Also, the temperature and solidification rate around the build area are the predominant factors that determine a metal�s resulting microstructure, which, in turn, dictates the material�s mechanical properties.

There is a need to control the thermal distribution throughout the manufacturing process. An innovative approach on direct digital manufacturing process is sought to manufacture uniform/desired microstructure, defect free, and near-net shaped aircraft components. The process is not limited to single beam melting technology, powder bed thermal design, or cooling system design, etc.

PHASE I: Develop the methodology and tools for a thermal managing system and demonstrate the feasibility of producing uniform/desired microstructure, defect free, simple-shaped materials with comparable forged mechanical properties

PHASE II: Refine/develop material processing controls and parameters which fabricate uniform/desired microstructure, defect free, and near-net shaped aircraft components. Develop and demonstrate a process control tool utilizing the thermal and micostructural models to control the process parameters of commercially available Direct Digital Manufacturing technologies.

PHASE III: These tools and methods could be used to qualify a broad range of metallic DDM parts for military and civilian applications.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Direct Digital Manufacturing (MDDM) is an emerging and innovative manufacturing process which creates metallic parts directly from powder metal. These metallic parts are intended to be used as the final product itself with minimal post-processing such as machining and surface finishing. DDM promises cost, time and efficiency benefits over traditional machining processes (in which material is removed using cutting tools) in the area of low production volumes, processes involving constant design iterations and manufacturing parts that have relatively complex geometric shapes. Additionally, as compared to traditional machining of metal parts, DDM technologies will allow engineers to create more efficient, creative, and innovative aerospace-related designs rapidly and accurately in which complex features and internal passages can be created that could not be created with traditional machining methodologies and techniques.

REFERENCES:
1. William Frazier, Don Polakovics, and Wayne Koegel, "Qualification of Metallic Materials and Structures for Aerospace Applications," JOM. March 2001.

KEYWORDS: Direct Digital Manufacturing, Thermal, Microstructure, Titanium

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