Lockheed Martin Proprietary Information

Imagine The Future:

Additive Manufacturing

in Aerospace

Jeanne Kerr

Director, Strategic Quality

Management

Lockheed Martin Space Systems

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Bob Fenolia

Sr. Quality Engineer

Strategic Quality Management

Lockheed Martin Space Systems

Copyright 2015 Lockheed Martin Corporation. All rights reserved

Additive Manufacturing is just a process,

albeit a really, really cool process

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Quality must approach Additive Manufacturing as a process; by controlling the inputs,

monitoring the process elements and verifying the outputs

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Creating the Future

EBM EB DM

Laser

Deposition

New

Alloys

Design

Database

High

Temp

Research &

Development

Large

Structures

Next Gen

Engineering

Designs

Spaceflight Propulsion

n

Satellites

Production and

Programs & Quality Engineering

Developing unique aerospace capabilities…

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What is a Process?

All personnel, equipment, materials, methods,

procedures, and environmental characteristics

that interact to produce an output.

Walter Shewhart (1931) wrote, “...a

phenomenon will be said to be controlled

when, through the use of past experience, we

can predict, at least within limits, how the

phenomenon may be expected to vary in the

future.”

What is Process Control?

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Process Inputs

Material Properties

Supplier Performance

Inspection Characteristics

Arcam Approach

• Additive Mfg Lab (AML) in Denver Arcam A2 Machined Installed 2013

• Released Material Specifications “Powder for Direct Mfg Deposition” (controls raw Ti powder material feedstock)

• Released Process Speciation “Additive Mfg with Electron Beam Melting - Powder Bed Fusion” (based upon feedback data generated during material allowables program)

• First components produced from Ti-6Al-4V, shear tie fittings for reflectors (right)

• Completing additional design allowables test program (characterizing post processing and fracture toughness)

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The Process Control

Study

Product & Process

Requirements

Use Advanced Quality

Planning (AQP) Tools

to Design the Product &

Process

Monitor

Effectiveness Make

Improvements

Implement

the Process

Output Customer /

Consumer

Achieve As-

Produced Quality

by ‘Designing It In’

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Process

Environment

System Performance

Inspection Characteristics

Process Control Elements example

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Wire Feed: • Material properties

• Source of Material

Electron Beam: • Power consumption

• Intensity

NDT inspection: • Material Properties

Environment: • Cleanliness

• Temperature

• Humidity

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What Causes Variability?

People Machines Methods

Measurement Environment Materials

Output

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AQP Tools / Control Methods

• Robust Product and Process Design Achieved

Through the Use of Experimental Design Methods

• Mistake-Proofing

• Automatic Control Systems

• Adjustment Charts

• Standardized Operations and Procedures

• Reliability Methods

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Process Outputs

Verification

Process Control Results

Methods of Verification

Reactive Methods

(weed out poor

quality)

Proactive Methods

(improve product quality)

Inspection

Qualification test

Acceptance test

Development test

Analysis (when done to improve a

design)

Process control (showing a process is

so well controlled that its products do

not need inspection)

Similarity (the right balance of test, process control and analysis)

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Predictability

• Process output affected only by common

causes of variation is stable and

predictable.

• Process output affected by common and

special causes of variation is unstable,

and therefore by definition,

unpredictable.

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Customer

Compliant

Affordable

Consistent, Repeatable, Reliable Product

Electron Beam Direct Manufacturing

• Digital Thread: CAD-to-Machine-to-Part

• Titanium 6Al-4V: High Value Material

• Affordability: 40-70% cost improvement

• Schedule: 20-80% lead time improvement

• Equivalent Performance: strength, fatigue,

fracture toughness similar to or better than

titanium forgings

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CAD Model

Deposition

Machining

Finished Part Reduce Cost and Lead Time of Large Titanium Parts By

50%

48% Cost Reduction 53% Cycle Time Reduction

Reflector Shear Tie Fittings

Propulsion Dome Demo

• EBDM Domes

• Heat treatment

• Final machine

• Weld spherical tank

• Proof pressure test

• Shown at White House event Feb 25,

2014 when the President announced

the next National Network of

Manufacturing Innovation (NNMI)

institutes

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Titanium Propellant Tank Dome

Advantages

• DM Accelerates schedule

• Baseline forged dome: 9-12 Mo lead time

• DM Dome Preform was made in 3 hours

• DM Dome is ~50% cost of forged dome

• Baseline forging limitation 46” diameter

• DM Dome does not have same size limitation

Ti Tanks (5) Base

Stock

Additive

Mfg

Material

CAD Design Direct Manufactured Propellant Tank Dome

• 16” scale demo manufacturing study

• Baseline tank domes are forged titanium

(~$60K each)

• Laser scan of DM part ‘bulls-eye’ on deposition

Copyright 2015 Lockheed Martin Corporation. All rights reserved

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