Develop, demonstrate, and transition prescriptive prototype qualification and fabrication requirements via the approach of design, build, machine, nondestructive evaluation (NDE), property test, and reporting.

Problem

Additive manufacturing (AM) processes are targeted as the next high-impact manufacturing process for NAVSEA parts and components, offering the capability to produce parts at low production volumes. To fully implement this manufacturing process, qualification and fabrication requirements must be developed. Some qualification and requirements have been established through previous project efforts, but NAVSEA has identified additional supporting processes and technology topics that need to be addressed to provide updates to NAVSEA Technical Publications.

Objective

The overall goal of the project’s three-year effort is to develop additional procedure qualification schemes/components, support process requirements, and pertinent fabrication requirements to update NAVSEA Technical Publications for both metal directed energy deposition (DED) and metal powder bed fusion (PBF) including electron beam powder bed fusion (EB-PBF), electron beam wire fed DED (EB-DED), and laser powder fed DED (PL-DED) thus accelerating implementation of these related technologies. The project also seeks to develop both prescriptive requirements and best practices where possible to improve metal AM process qualification affordability, avoiding the need for “special” procedure qualifications that increase cost and schedule.

Technical Approach

EWI, the NAVSEA Technical Warrant Holder (TWH) for AM, and the Naval Surface Warfare Center Carderock Division (NSWCCD) has identified a list of supporting processes and technology topics that need to be addressed to complete development of these NAVSEA Technical Publications. During this Phase I effort, the team plans to leverage previous work that addressed procedure qualification schemes for arc DED processes using integrated and nonintegrated build platforms and for both single-sided and double-sided build applications.

The initial work established the procedure qualification schemes for standard quality build (SQB) designs, NDE procedure map, property matrix, and qualification records for each application and process combination. Because these AM processes cover a range of feature size capabilities that are defined by minimum bead width, the SQBs are designed for full scale (≥ 5mm) and subscale features (2-5mm). The previous efforts identified the need to develop mini SQBs for processes with features approximately < 2mm bead width.

The focus for this Phase I effort is in developing NDE requirements for the SQBs, developing mini SQBs and the test specimen designs. By utilizing these designs, EB-PBF build layout, test array, and demonstration builds are being completed along with EB-DED and PL-DED procedure qualification scheme and demonstration builds. The results of the Phase I tasking support the development of the PBF and DED Technical Publications that continue to be completed throughout the overall three year/three phase project.

Project Participants

Project Principal

Other Project Participants

  • NAVSEA/Carderock

Public Participants

  • U.S. Department of Defense

Project Summary

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