Measurement demonstration component provided by Corpus Christi Army Depot (CCAD)
Interest in Laser Powder Feed Directed Energy Deposition (LPFDED) repaired components has grown, but it is still a maturing technology. This project focuses on the development of a LPFDED repair technology that can be cost-effectively and consistently applied to a wide range of high-reliability applications with a certifiable, approval-based method.
Problem
There is a need for a reliable and robust additive manufacturing (AM) repair method for military aircraft related components manufactured from Ti-6Al-4V. Depending on the component, conventional repair methods may not always be feasible or reliable. As a result, interest in Laser Powder Directed Energy Deposition (LPDED) to solve this problem has grown. LPDED is a maturing technology, however, lacking specifications, best practices, procedures, and process controls.
Objective
The goal of this project was to facilitate the adoption of AM for flight-worthy repairs by restoring the Ti-6Al-4V component function without compromising structural integrity. Restoration of the component function was achieved by the development of an LPDED repair methodology that could be cost-effective and consistently applied to a range of applications. The project also included the coordinated integration of available, past and ongoing, LPDED development efforts into a centralized directed energy database (DEDatabase).
Technical Approach
This project consisted of four phases to develop LPDED for certifiable component repair and maintenance:
- Formation Phase – Established a DEDatabase structure and performed a gap analysis based on prior investigations, along with Air Force repair requirements.
- Development Phase – Demonstrated and refined all appropriate repair capabilities down-selected from candidate technologies.
- Testing Phase – Designed and executed a metallographic and mechanical testing program to generate design data for generic U.S. Department of Defense (DoD) repair configurations utilizing the down-selected capabilities.
- Documentation and Deployment Phase – Populated the DEDatabase with accumulated process data and results, and summarized the LPDED repair process best practices for distribution to America Makes stakeholders.
Project Participants
Project Principal
Other Project Participants
- Pennsylvania State University ARL (PSU ARL)
- Concurrent Technologies Corporation (CTC)
- United Technologies Research Corporation (UTRC)
- Connecticut Center for Advanced Technology
- University of Connecticut
- Corpus Christi Army Depot (CCAD)
- TechSolve
- GE Aviation
- Lockheed Martin
- Rolls Royce Corporation
- EWI
Public Participants
- Air Force Research Laboratory (AFRL) Materials and Manufacturing Directorate, Manufacturing and Industrial Base Technology Division
