Goal is to Improve Process Control for Qualifying Complex Parts and Reduce Costs
Youngstown, Ohio — December 18, 2018. America Makes is proud to announce the awardees of a Directed Project Opportunity on advancing additive manufacturing (AM) post-processing techniques (AAPT), funded by the Air Force Research Laboratory (AFRL), Materials and Manufacturing Directorate, Manufacturing and Industrial Base Technology Division. Driven by the National Center for Defense Manufacturing and Machining (NCDMM), America Makes and AFRL awarded $1.6M to fund two awards with at least $800K in matching funds from the awarded project teams for total funding worth roughly $2.4M.
The focus of the AAPT Directed Project is of particular interest to AFRL. In order to expand the use of Selective Laser Melting (SLM) for critical parts, a better understanding of the available techniques is needed to achieve qualified parts and certified processes. The current lack of a consensus of best practices for material handling and post-processing leads to high variability and massive qualification challenges, invariably leading to higher costs to adopt and employ AM technologies. Through the AAPT Directed Project, AFRL specifically seeks to address two main issues. First, quantify the mechanical performance debit of using as built SLM surfaces to fabricate high-temperature nickel super alloy canonical features, such as thin walls and narrow flow channels. Second, quantify the effectiveness of Hot Isostatic Pressing (HIP) when producing high-temperature nickel super alloy canonical features, such as thin walls and narrow flow channels.
Subject to the finalization of all contractual details and requirements, the selected America Makes AAPT Directed Project Opportunity Awardees are:
Awardee #1: Arizona State University
Led by Arizona State University, in conjunction with Quintus Technologies; Phoenix Heat Treating, Inc.; and Phoenix Analysis & Design Technologies, Inc., this project team seeks to gain a better understanding of how mechanical properties, such as stiffness, strength and fatigue life for as-built structures (without machining), change as a function of size in metal AM. Additionally, the project team seeks to explore and pursue the fundamental reasons for how these findings change with respect to post-processing steps, such as HIP. In doing so, the project team anticipates being able to identify the relationships among process, specimen size, and post-processing to enable improved certification of AM processes and materials.
Awardee #2: ASTM International Additive Manufacturing Center of Excellence (AM CoE)
Led by the ASTM AM CoE, a collaborative, which includes ASTM International, Auburn University, EWI, the National Aeronautics and Space Administration (NASA), Wichita State University – National Institute for Aviation Research (NIAR), in conjunction with Quintus Technologies, Carpenter Technologies Corporation, Aerojet Rocketdyne, Rolls Royce Corporation, Honeywell Aerospace, GE Aviation, and Raytheon, the project team seeks to determine the mechanical performance debit of using as-built AM components, understand how this changes with application of HIP, test the values by burst testing thin wall components with narrow flow channels, and publish standards around these results in order to close industry known gaps.
“America Makes and AFRL are pleased to announce Arizona State University and ASTM International AM CoE as the AAPT Directed Project Opportunity awardees,” said Rob Gorham, America Makes Executive Director. “These project teams have outlined interesting approaches to better understanding mechanical and material properties during heat treatments. As a result, we anticipate the projects will yield important gains in process control, certified processes, and the qualification of materials and parts, which will all be instrumental in reducing post-processing costs—one of the biggest barriers to the wider adoption of AM technologies. On behalf of all of us at America Makes and AFRL, we extend our congratulations to Arizona State University and the ASTM International AM CoE and their respective teams.”
The anticipated start date of the projects is January 2019.
For more information on the AAPT Directed Project or how to become an America Makes member, please visit the America Makes Web site at https://americamakes.us.
About America Makes
America Makes is the National Additive Manufacturing Innovation Institute. As the national accelerator for additive manufacturing (AM), America Makes is the nation’s leading and collaborative partner in AM and 3DP technology research, discovery, creation, and innovation. Structured as a public-private partnership with member organizations from industry, academia, government, non-government agencies, and workforce and economic development resources, we are working together to innovate and accelerate AM to increase our nation’s global manufacturing competitiveness. Based in Youngstown, Ohio, America Makes is the first Institute within the Manufacturing USA infrastructure and is driven by the National Center for Defense Manufacturing and Machining (NCDMM). For more information about America Makes, visit americamakes.us.
NCDMM delivers innovative and collaborative manufacturing solutions that enhance our nation’s workforce and economic competitiveness. NCDMM has extensive knowledge and depth in manufacturing areas—both commercial and defense—continually innovate, improve, and advance manufacturing technologies and methodologies. Our experienced team specializes in identifying the needs, the players, the technologies, and processes to attain optimal solutions for our customers. We connect the dots. That’s the NCDMM methodology. NCDMM also manages the national accelerator for additive manufacturing (AM) and 3DP printing (3DP), America Makes and the V4 Institute. For additional information, visit the NCDMM at ncdmm.org.
About Arizona State University
Arizona State University has developed a new model for the American Research University, creating an institution that is committed to access, excellence and impact. ASU measures itself by those it includes, not by those it excludes. As the prototype for a New American University, ASU pursues research that contributes to the public good, and ASU assumes major responsibility for the economic, social and cultural vitality of the communities that surround it. For more information, visit asunow.asu.edu.
About ASTM International
Committed to serving global societal needs, ASTM International positively impacts public health and safety, consumer confidence, and overall quality of life. We integrate consensus standards—developed with our international membership of volunteer technical experts—and innovative services to improve lives…Helping our world work better. ASTM International officially launched the ASTM International Additive Manufacturing (AM) Center of Excellence (CoE) in July 2018 to support R&D that advances additive manufacturing standards, which in turn will drive commercialization of cutting-edge additive manufacturing technologies. The ASTM International AM CoE is a collaboration comprised of ASTM International, Auburn University, EWI, the National Aeronautics and Space Administration (NASA), Wichita State University – National Institute for Aviation Research (NIAR) and the UK-based Manufacturing Technology Centre. For more information, visit astm.org.