Portfolio Status: Projects In Progress

5001.004.001.004 Inspection Using In-Situ Height Mapping

March 23, 2024

Develop a framework to leverage in-situ process monitoring data to virtually reconstruct the part and inspect complex internal features for fidelity and dimensionality. Acquired data can be...

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5541 Fatigue Allowable Curves and Effects of Texture and Thickness (FACETT)

March 20, 2024

The project aims to empirically derive and numerically predict high cycle fatigue design allowables for textured thick-and-thin-walled Ti-6Al-4V additively built material. Using these datasets,...

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5567 Improving LPBF Operational Qualification through Software Automation

February 27, 2024

This project aims to create a financial and productivity-focused qualification step change for AM. Combining Siemens production volumes, experience, and problems through an innovative software and...

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5541 Team Red: Thorough Evaluation of AM with Rigorous Expertise and Data

February 27, 2024

This project will demonstrate the ability to rapidly and affordably update and/or establish a qualified AM process that can allow for changes in key AM process, post-processing, and/or material...

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5560 Thin Wall Testing Methodology for High Temperature Materials

February 27, 2024

This material testing program seeks to expand the USAF CoCr material property dataset by characterizing material behavior in thin wall as-printed features. Defining the material allowables for...

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5541 Boeing Baseline Delta Qualification Program

February 27, 2024

The primary objective of this project is to establish a baseline for the effort needed to qualify a machine at a vendor for laser powder bed fusion (LPBF), and then demonstrate the process...

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5541 Rapid Qualification Pathway for Metal Additive Manufacturing Using Laser Powder Bed Fusion (PBF-L) for Critical Applications

February 26, 2024

Develop a rapid qualification framework for metal AM laser powder bed fusion (PBF-L) processes that can be achieved with a data-driven solution to minimize the reliance on costly and...

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Raytheon Technologies

5541 Model Enabled Delta-Qual (MEDEL-QUAL)

February 23, 2024

The MEDEL-QUAL team will develop and demonstrate a delta qualification methodology that utilizes advanced empirical, analytical, and numerical tools to model the process-microstructure-property...

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5541 Delta Qualification Innovation (DQI) for Ti-6Al-4V Laser Powder Bed Fusion

February 23, 2024

This project will demonstrate a delta qualification approach for statistical equivalency of static allowable data and develop a statistical database and framework that provides A/B basis...

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5541 Demonstration of Novel Methods for Effective AM Process Qualification/Requalification

February 23, 2024

The objective of this project is to develop an effective, streamlined process for requalifying laser powder bed fusion (LPBF) Ti-6Al-4V and any components manufactured from this material after the...

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5567.002 Accelerating Control and Certification: Enhancing Laser-PBF and Electron Beam-PBF Operation Quality via Real-time Analytics, Technological Integration, and Experimental Platforms for a Resilient Supply Chain (ACCELERATE)

February 23, 2024

The team aims to establish a reliable OQ framework for electron beam power bed fusion (E-PBF) and L-PBF, in line with the Air Force’s specifications, DoD Instruction 5000.93. To achieve this,...

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5567.001 Methods and Approaches for Sustainable AM Operations, Operational Qualification (OQ)

February 23, 2024

Wichita State University National Institute for Aviation Research (WSU NIAR) has composed a program that will establish a sustainable OQ process to be widely implemented within the organic and...

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