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Jude RestisEngineering ManagerBoeing Additive Manufacturing
1
Additive Manufacturing OverviewThe State of Additive Manufacturing
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What is Additive Manufacturing (AM)AM at BoeingChallenges with metal AM Safety Certification Surface finish Process development Design allowables
Questions
2
Agenda
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A Brief History of Additive Manufacturing 1890 – Blather patents a technique for making molds for topological relief maps by cutting
and stacking a series of wax plates
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1951 – Munz proposed system to expose a transparent photo emulsion in a layerwise fashion based on a cross section of a scanned object
1968 – Swainson proposed technique to directly form plastic pattern by selective, three dimensional polymerization of a photosensitive polymer at the intersection of two laser beams (photochemical machining)
1971 – Ciraud proposed a powder-based process for producing 3D objects by selectively melting or sintering material with a local heat source (laser, e-beam, etc)
Bourell, RapidTech2009Slide courtesy of Dr. C. Duty - ORNL
1979 – Housholder proposes first layer-based powder approach for selectively solidifying a portion of layer with a laser beam and building upon successive layers
A Brief History of Additive Manufacturing
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1981 – Kodama published report of layer-based photopolymer cure system using masked UV light source or optical fiber
1982 – Herbert at 3M develops similar photopolymer cure system using a scanning laser beam directed by mirrors
1983 – Charles Hull (“Father of Modern 3D Printing”) developed the technology for printing physical 3D objects from digital data (CAD/CAM files) using photosensitive polymers
1986 – Charles Hull founded 3DSystems and developed the first commercial 3D Printing machine – called SLA for StereoLithography Apparatus
1986 – Carl Deckard and Joe Beaman develop selective laser sintering (SLS) for plastic powders at the University of Texas
1979 – Prof Nakagawa of Tokyo Univ used laminate techniques to produce metal tooling (blanking, press form, injection molding, etc)
A Brief History of Additive Manufacturing
1988 – Scott Crump invented Fused Deposition Modeling (FDM) that builds parts by heating and extruding polymer filaments
1989 – Scott Crump founded Stratasys
1991 – Helisys sold the first Laminated Object Modeling (LOM) system which selectively cuts adhesively coated paper with a laser to form objects
1991 – Stratasys sold the first FDM machine “3D Modeler”
1992 – DTM sold the first selective laser sintering (SLS) system, the SinterStation 2000
1993 – MIT patented “Three Dimensional Printing” techniques that uses binder jetting to bond ceramic powder together (licensed to Z Corp in 2005, later acquired by 3DSystems in 2012
2009 - Fused Deposition Modeling (FDM) printing process patent expired
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AM process terminology per ISO/ASTM 52900
What is Additive Manufacturing?
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AM process terminology per ISO/ASTM 52900
Material Extrusion (aka Fused Filament Fabrication “FFF)
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Typical Materials • ABS• Ultem • Polycarbonate • PPSF• PLA • Nylon 12 R
R
Pros• Wide variety of internal geometry options• Higher temperature materials (Ultem)• Large build volume • Machines can be inexpensive
Typical Applications• Shop aids and tools • Fit check & mockup parts • Prototyping• Flight hardware in the future
FFF Process Description
Example
Cons• Roughly 50% knock down in mechanical
properties in the Z direction (currently)• Slow build rate • Requires support material • Parts will always have some level of porosity
Described as a hot glue gun affixed to a three-axis machine head
FFF environmental control system (ECS) duct flow test article
Applications with Material Extrusion (aka Fused Filament Fabrication “FFF”)
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Material Extrusion
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AM process terminology per ISO/ASTM 52900
Vat Photopolymerization (aka Stereolithography “SLA”)
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Pros• Dimensionally accurate process• Smooth surface finish• Large build volume • Isotropic mechanical properties
Typical Applications• Shop aids and tools • Fit check & mockup parts • Prototyping• Wind Tunnel models• Molds and patterns
SLA Process Description
Example
Cons• UV exposure degrades the material overtime. • Requires support material
Typical Materials (Photopolymers)• Somos Next• Somos Watershed• Accura 60• Accura Xtreme
An ultraviolet laser cures liquid resin on top of a vat of liquid resin.
SLA Full scale mechanical mockup
Vat Photopolymerization (aka Stereolithography “SLA”)
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Vat Photopolymerization (aka Stereolithography “SLA”)
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3D Systems SLA 5000 in operation
Vat Photopolymerization (aka Stereolithography “SLA”)
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Designer: David Hass AM Support: Siyani McFall
SLA ECS plenum (White) used to functionally test airflow and noise in the cabin.
Vat Photopolymerization (aka Stereolithography “SLA”)
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Material Jetting
AM process terminology per ISO/ASTM 52900
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RR
Pros• Dimensionally accurate (.001” layer thickness) &
600 dpi material deposition • Smooth surface finish • Can fabricate with hard and soft materials at the
same time in the same part• Large build volume
Typical Applications• Shop aids and tools • Fit check & mockup parts • Prototyping• Wind Tunnel models• Molds and patterns
Material Jetting Process Description
Example
Cons• Support material removal can be labor intensive• UV exposure degrades the material overtime.
Typical Materials• Vero family (Hard)• Tango family (Rubber like)• Digital materials (blend of several materials)
Uses an epoxy-based photopolymer deposited like an inkjet printer and cured by an ultraviolet lamp after every layer.
Demonstration pieces for multiple material capability
Material Jetting
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Material Jetting
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Thermoplastic Powder Bed Fusion (aka Selective Laser Sintering “SLS”)
AM process terminology per ISO/ASTM 52900
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RR
Pros• Can be used for flight hardware• No support material required• High temperature materials available (PEKK)• Can recycled material • Can utilize entire build volume
Typical Applications• Flight Hardware • Shop aids and tools • Fit check & mockup parts • Prototyping• Wind Tunnel models
SLS Process Description
Example
Cons• Parts may warp in fabrication process• Rough surface finish • Need raw material controls (facility can get
dusty)
Typical Materials• Nylon 11 (blend with CF, AL, Fire retardants etc.) • Nylon 12 (blend with CF, AL, Fire retardants etc.) • PEKK (blend with CF)
Uses a laser to sinter layers on top surface of a bed of thermoplastic powder.
Selective Laser Sintered Articulating flap assy
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Thermoplastic Powder Bed Fusion (aka Selective Laser Sintering “SLS”)
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interior linings
Thermoplastic Powder Bed Fusion (aka Selective Laser Sintering “SLS”)
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Flight Test Sensor Mount Bracket
SLS Carbon Fiber filled Nylon 11
Thermoplastic Powder Bed Fusion (aka Selective Laser Sintering “SLS”)
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Power Feed Air Drilling template Lightweight with unitized vacuum features for foreign object removal
Thermoplastic Powder Bed Fusion (aka Selective Laser Sintering “SLS”)
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Metal Powder Bed Fusion
AM process terminology per ISO/ASTM 52900
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RR
Pros• Wide variety of metallic alloys (ferrous & non
ferrous) • Can design in internal geometry such as fluid
pathways • Ability to fabricate very fine details
Typical Applications• Shop aids and tools • Fit check & mockup parts • Prototyping• Wind Tunnel models• Molds and patterns
Example
Cons• Relatively small build volume • Support material removal can be labor intensive• Parts can warp if not stress relieved properly
GE’s DMLS Fuel nozzle for the LEAP engine
DMLS & EBM Process Description
Uses a laser or electron beam to melt layers on bed of metallic powder
Typical Materials• Stainless Steels• Titanium • Aluminum • Inconel
Metal Powder Bed Fusion
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Laser sintered radiator for an F1 race car EOS M270
Metallic Powder Bed Fusion (Direct Metal laser sintering “DMLS”)
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Additive Manufacturedorthopedic implant (EBM)
DMLS heat exchanger
Metallic Powder Bed Fusion (Direct Metal laser sintering “DMLS”)
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Functional test of aft fairing redesign for 747
DMLS 15-5 Stainless Steel Designer: Genesis PilarcaAM Support: George Robinson
Metallic Powder Bed Fusion (Direct Metal laser sintering “DMLS”)
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EOS: e-manufacturing solutions
Concept Laser (Airbus)
Concept Laser(Laser Zentrum -Airbus)
Solid Thinking s/w Sentinel-1Satellite bracket
EOSAirbus Engine Door Hinge
Concept Laser(Airbus Advanced Concept)
Renishaw(Engine component)
Metallic Powder Bed Fusion (Direct Metal laser sintering “DMLS”)
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Directed Energy Deposition (DED)
AM process terminology per ISO/ASTM 52900
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Up close view of a directed energy deposition process in action (powder feed using a laser power source)
Directed Energy Deposition (DED)
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RR
Pros• Ability to fabricate very large metal parts • Theoretically can fabricate primary structure • Reduces the buy-to-fly ratio for expensive alloys
such as Titanium• 5 axis capable & faster build speeds compared
to DMLS and EBM
Typical Applications• Repair existing components (turbines)• Large structure parts
Example
Cons• Must post machine all parts • Mechanical properties sensitive to process
variability • Can build up larger thermal stresses during
fabrication causing warp or fracture
Typical Materials• Stainless Steels• Titanium • Aluminum • Inconel
RPM Innovation’s conference demo part. Metal powder and a laser beam melt source was used to fabricate the part.
DED Process Description
DED utilizes focused energy (either an electron beam, plasma beam, or laser beam) to fuse materials by melting as the material is being deposited. Powder or wire feedstock can be used with this process.
Directed Energy Deposition (DED)
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Fully post machined part
Initially deposited material (Wire Feed System from Sciaky Inc.)
Directed Energy Deposition (DED)
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Large Scale Additive Manufacturing (LSAM)
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BAAM – “BIG AREA ADDITIVE MANUFACTURING” - OAK RIDGE NATIONAL LABORATORYNow called LSAM
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LARGE SCALE ADDITIVE MANUFACTURING
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BAAM – “BIG AREA ADDITIVE MANUFACTURING” - OAK RIDGE NATIONAL LABORATORY
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M-RAM-6Modular Robotic Additive Manufacturing, 6-AxisHayden Osborn - ATS
ATS Additive ManufacturingBOEING PROPRIETARY
Material: Carbon Fiber filled ABS pellets
Output: Up to 150 lbs of plastic per hour.
Approximate Build Volume: 3ft X 8ft X 50ft(can be increased by adding more gantry rails)
LARGE SCALE ADDITIVE MANUFACTURING
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What is Additive Manufacturing (AM)AM at BoeingChallenges with metal AM Safety Surface finish Certification Parameter development Design Allowables
Questions
38
Agenda
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About Boeing
| 39
$93.4 BILLION
in 2017 revenues
Products and services support to customers in more than
150 COUNTRIES
of commercial airplane revenue
historically from
customers outside the
United States
Manufacturing, service and technology partnerships with companies around
the world
Contracts with more than
20,000 suppliers and
partners globally
Research, design and technology-
development centers and programs in
multiple countries
70%across the United States and
in more than
65 COUNTRIES
140,000
BOEING EMPLOYEES
Approximately
Boeing 7-series family of airplanes leads the industry
COMMERCIALAIRPLANES
World’s largest manufacturer of military aircraft and satellites and
major service provider to NASA
Large-scale systems integration, networking technology and
solutions provider
DEFENSE, SPACE & SECURITY
GLOBALSERVICESA dedicated services
business focused on the needs of global defense, space and commercial
customers
Partnering across the planet for mutual prosperity – and to change the world
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3 Focus Areas3 Focus Areas
17 U.S. Site Locations17 U.S. Site Locations
Boeing Additive Manufacturing by the Numbers
20Number of Boeing sites worldwide With 3-D printing facilities (U.S.,Canada, Australia & U.K.)
20Number of Boeing sites worldwide With 3-D printing facilities (U.S.,Canada, Australia & U.K.)
Over 20 Years of Experience in Additive Manufacturing
60,000+3D-printed parts flying on both commercial and defense programs
60,000+3D-printed parts flying on both commercial and defense programs
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Boeing Additive Manufacturing Metallic
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Boeing Additive Manufacturing Opportunities
StructuresMajor assembliesBody sectionsMovable wing
sectionsDoorsFlight control
surfacesFuselage
InteriorsPassenger seatsCabin systemsGalley inserts InteriorsCargo systems
SystemsAvionicsFlight systemsHydraulicsWheels and brakesLanding gearEnvironmental
control systemsElectrical systems
ServicesSparesTechnical &
Engineering servicesCustomer support InternalNon-production
Common CommoditiesMachined partsAssembliesTubingWiringToolingRaw materialsStandards
PropulsionEnginesStrutsNacelles
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What is Additive Manufacturing (AM)AM at BoeingChallenges with metal AM Safety Certification Surface finish Process development Design allowables
Questions
43
Agenda
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Safety in AMAluminum and Titanium are both explosive and flammable Smaller particle sizes increase flammability risk Aluminum reacts with water Both can be ignited by static sparks Metal Fires are difficult to fight
– Isolate first, and then fight with Class D Extinguisher only when necessary
NFPA 484 – Standard for Combustible Metals Define the Hazard to determine severity
– ASTM E1226 – Explosibility of Dust Clouds (Kst)
Mitigate the Hazard appropriately– Redesign equipment, implement process controls, and then define PPE– Assume the ignition source, then eliminate one aspect of an explosion
to eliminate risk
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Safety in AMFacilities Requirements Bond and Ground all equipment and operators
– Conductive flooring is not required, but provides a great common connection– Wrist straps and bonding straps are necessary for every operation with powder
Monitor Humidity: Static increases exponentially below 30%
Housekeeping Keep all surfaces clean, small explosions are aggravated by dust build up
– Rule of thumb, keep dust below 1/32” deep
Use explosion proof immersion wet-separator vacuums. – Never blow down parts or equipment with compressed air
PPE Eye glasses ESD-rated or wiped with staticide Safety toes, ESD rated if the floor is conductive SD and FR clothing Latex gloves
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Certification of Flight Structure
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Sources of Airworthiness Compliance Guidance and Requirements
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USAF Aircraft Structural Integrity Program (ASIP) MIL-STD-1530D
DoD Airworthiness Certification Criteria (MIL-HDBK-516C)
Joint Services Specification Guide JSSG-2006
NASA Std. for AM Spaceflight Hardware … MSFC-STD-3716 USAF Process for Deploying
New or Substitute Materials … AWB-1015FAA Federal Aviation
Regulations, Part 25, …
US Navy Detail Specification for Aircraft Weapon System
Qualifying of Metallic Materials and Structures for Aerospace Application JOM
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Structural Airworthiness Compliance Steps
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NDE
Requirements & Design Criteria
Material & Process Spec
Characterized Material & Allowables
Test Verification
Demonstrated Manuf. Technology Can parts be built successfully using AM?
Is the material and process controlled?
Do we understand the requirements?
How are the part design values determined?
What verification tests will be used?
How do we make sure the parts are free of detrimental defects?
Maintenance PlanWhat are the supportability needs for the AM part?
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Compliance Details
Stable & Repeatable Processes are a Prerequisite for Aerospace UsageIndustry StandardsBoeing Materials and Process Specifications
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Material & Process Spec
Demonstrate the Ability to Build Complex PartsDemonstrate Design OptimizationCost of Failure will Quickly Undercut any Projected Benefit
Demonstrated Manuf. Technology
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Compliance Details
50
S-Basis Static Allowables
A-Basis Static Allowables
Durability Design Values
DamageTolerance
Design Values
S
N
DK
dadN
Safety of Flight
Not Safety of Flight
Fracture Critical Traceable
Fracture Critical
Durability / Maintenance Critical
Normal Controls
Characterized Material & Allowables
Allowables and Data Requirements Depend on Application Criticality
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Compliance Example
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Characterized Material & Allowables
Sample Test Specimen Build – AlSi10Mg
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Compliance Example
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Characterized Material & Allowables
Evaluation of the Effect of Defects on Structural Performance Machined Surface Fatigue Specimen As Deposited Surface Fatigue Specimen
Fatigue Crack Growing From Internal Defect
Fatigue Crack Growing From
Surface
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Compliance Example
53
Evaluation of AM Non-Destructive Inspection Capabilities
NDE
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Surface Finish
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The Mantis Shrimp Packs a Powerful PunchUsing Water Cavitation as a Weapon
Boeing & Tohoku University Development of a Novel Surface Finishing Method for Additive Manufactured Metal Parts Requiring Fatigue Resistance: Water Cavitation Abrasive Surface Finishing and Peening
Surface Finish
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Cavitation vs. Shot Peening
http://eswt.net/wp-content/uploads/2011/10/cavitation.gif
Cavitation Peen Shot Peen (steel ball)
Microjet
Water Vapor – Incubation Stage for Cavities
X
Wikepedia CommonsFree Media
Wikepedia CommonsFree Media
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Schematic diagram of abrasive cavitating jet
Water nozzleMixing nozzle
Abrasive
Outlet bore
High pressur
e water
Pre-mix tank
Test specimen Standoffdistance
High pressure
water
Abrasive nozzle
Outlet part
Cavitation Abrasive Surface Finishing & Peening
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Surface Finishing Cavitation peening “wraps” around part edges
and allows treatment of blind surfaces, which is a step-change improvement over current techniques
Cavitation abrasive finishing offers an inexpensive, superior surface smoothing process for complex part configurations to enable design optimization of primary metal structure produced using AM
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Conventional Design
AM Optimized Design
AM Optimized Part (Actual)
By Ghuczek - Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=38535176
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Settling tank Test chamber
Ti LM Additive Manufacturing Parts Treated With Cavitation Surface Abrasion
Before Treatment
After Treatment – 30 Seconds Pass
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CASF Test Ti 6-4 AM Test
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Cavitation Peening Preliminary 316 CRES Fatigue Test Results
10000 100000 1000000 10000000250
300
350
400
450
500
Appl
ied
bend
ing
stre
ss s
a M
Pa
Number of cycles to failure Nf cycle
S-N curve
Cavitation peening
Shot peening
Laser peening
Water jet peening
Not-peened
H.Soyama, J. Mater. Processing Tech., 269 (2019), pp. 65-78.
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Cavitation Peening Test of Titanium 6Al-4V Aircraft Part
Top Side
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MMPDS Handbook is an accepted source for metallic material allowables, recognized by the Federal Aviation Administration (FAA), and all other regulatory agencies
Stable and repeatable material covered by a fixed specification is a must before allowables development can begin
No current approved MMPDS guidelines for AM by which allowables can be generated. Primary concerns expressed by the MMPDS How is the material from which test specimens are extracted shown to be representative of the material
expected to be seen in the final production components? If purpose-built witness coupons are used for material characterization, how are the coupon material
properties determined to be representative of the part’s material properties? How was the effect of recycled powder accounted for in establishing the material design values?
Metallic Materials Properties Development and Standardization (MMPDS) Guidelines for AM Statistically Derived Static Design Values
63
Design Allowables
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Process Development
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Develop requirementsMaterials development and characterizationProcess modelingDesign tools and softwareConstruction constraintsPost processingMachine qualification, certification and standardization
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Process Development
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Questions?