Unclassified
28 July 2015
Quality Metal Additive Manufacturing
(QUALITY MADE)
Enabling Capability
Billy Short
Logistics Program Manager
QUALITY MADE EC Manager
Expeditionary Maneuver Warfare and
Combating Terrorism Department
billy.short@navy.mil
DISTRIBUTION A. Approved for public release:
distribution unlimited.
Operational Challenges
Unclassified
DISTRIBUTION A
Naval Platform and Systems Operational Availability: Decreased
platform availability due to an increasing number of part challenges
that PMs are facing.
① Challenges include very long Mean Logistics Delay Time for limited
production parts.
② Lack of commercial interest in low volume complex fabrication work and
significant delays in contracting and workflow.
③ Increasing pressure on organic manufacturing capability. As an example,
Fleet Readiness Centers (FRCs) produce over 120,000 manufactured items
per year.
④ Naval Platform and Systems Total Ownership Cost: High cost for limited
production runs to make problem parts; many of those are cast
components. This may also include large investments to create special
tooling and complex castings.
3
Operational Challenges
Unclassified
DISTRIBUTION A
• Common Issues Across all Platforms:
•Aging fleets with severe parts supply issues. Examples: Amphibious Assault
Vehicle will be 51 years old at the end of service life & aircraft will have
14,000 hours & designed for 6,000.
•Higher failure rates; new failure modes; exigent parts demand for critical
components
•Systems down/deadlined for part obsolescence issues; decreasing vendor
supply base
•Increase in components that fail that were never expected to be repaired or
replaced
Stakeholders/Mission: Depots and FRCs are increasingly making parts
to combat these challenges. FRC/Depot mission includes producing parts to
improve maintenance efficiency. They need new technologies to enable the
reliable and cost-effective production of low volume parts.
4
AM Injection: Depot Level Maint.
Supported by Warfare Centers
Unclassified
DISTRIBUTION A
① Early transition of ICME / digital
design tools
• Push upgrades
• Support tooling before parts
② Installation of sensors on AM
machines
③ Technical support to part
demonstrations
5
System Boundaries
(Assumptions)
Unclassified
DISTRIBUTION A
• Not addressing:
– New AM machines; larger build volumes; faster
build rates
– Performing qualification / certification
– Cyber
– Expeditionary use / shipboard integration
Need to keep the system manageable
6
FY17-20 Program Goals
Unclassified
DISTRIBUTION A
• Enhance quality and reliability of metal additive
while addressing key Naval issues
– Build Naval confidence in material properties for critical
metal parts
– Improved design and quality control tools & processes
• AM for Naval materials (Ti-64, AlMgSi, SS 316L casting
analogs)
– Material properties better than cast and comparable to wrought
• Achieve desired volume/geometry
• Reduce residual stress
• Improve fatigue properties
– Support speedy qual/cert
7
FY17-20 Program Goals
Unclassified
DISTRIBUTION A
• Improved AM design by gaining
– From an enhanced understanding of the correlation of
materials properties to AM processes
– Reduce required redesign iterations before an acceptable
design is achieved
– Establish an upper and lower control limit for critical AM
process parameters for a successful build
• In situ sensors and closed loop process controls to
ensure a quality build
– Control AM process parameters to control microstructure,
volume, and geometry
– Collect build data to support qual/cert
8
Unclassified
EC Synopsis
DISTRIBUTION A
4 years, FY17-20
Mr. Billy Short, ONR-30
Dr. William Mullins, ONR-33
M&S and Design Tools
Quality Control
Start: TRL 4
End: TRL 6
Start: TRL 4
End: TRL 6
Transition Models & Part Designs to
NSWC/NAVAIR/Industry
Unclassified
Dr. Ignacio Perez, ONR-33
Transition Process / Control Suite
to FRCs/Depots/Industry
Likely Acq Strategy; Defined in BAA
(~2) Phase Is (for both ICME & QC), down-selecting to (1) Phase II
9
ICME Overview
Integrated Computational
Materials Engineering
(ICME)
----------------M&S & Design Tools
Interface to Closed Loop Controls
Unclassified
DISTRIBUTION A
• Model the AM process
• Predict resulting
microstructure
• Predict material
properties (stress,
fatigue, etc.)
• Predict part performance
• Optimize build package
• Accelerate process
acceptance
(T) Titanium, Aluminum, (O) Steel
Alloy Casting Analogues for
2 different AM processes
10
Closed Loop Overview
• Thermal cameras & other
in situ sensors
• Handoff from models
Melt Pool Illustration
– Upper and lower limits of
processes for a
successful build
• Close the loop to control
the build quality
Unclassified
DISTRIBUTION A
Interface to AM Machine
Closed Loop
Process
Controls
Titanium
Microstructure
Sample Sensor Info
•
•
•
•
•
•
Heating rates
Peak temperature
Cooling rate
Melt pool dimensions &
solidification contour
Surface shape & roughness
Porosity
Interface from ICME
Microstructure and mechanical properties are determined by thermal history
11
QUALITY MADE EC
Unclassified
DISTRIBUTION A
• Fabricate quality part
demonstrators with
Air, Ground, and Sea
communities
• PEO(A) (H-1 Helos)
• PEO-Land Systems (PM AAA)
• PEO Ships (LPD-17)
12
Challenges
Unclassified
DISTRIBUTION A
• Challenges:
– Defining the boundaries of the problems and sticking
to it (mission creep)
– Open vs Closed AM architectures
– ICME across a variety of AM processes and materials
• Self limiting to (2) processes and (2) threshold material (Al &
Ti cast analogs with an option for stainless steel).
– Getting the physics right to inform the design and
build at the optimal level of abstraction
• Informed by the physics while maintaining computational
efficiency, where required
– Integration / interface between ICME products and
Closed Loop Controls
– Continuing to develop framework to support later
rapid qualification and certification in acquisition
13
Next Steps
Unclassified
DISTRIBUTION A
• Provide us feedback! Ask questions.
• Post all industry day briefs on registration website
• https://www.onlineregistrationcenter.com/regist
er.asp?m=4269&c=113
• Open ONR website to allow communication to
government and teaming
• Refine Broad Agency Announcement
– White Papers
– Downselect & seek full proposals
– Final selection
• Initiate contracting actions (up to 12 months)
• Program start 1 Oct 2016
14
Backups
Unclassified
DISTRIBUTION A
15
Validation and Verification Requirements
Requirements for finished
product quality and
properties
Integrated System
Demonstration and
Validation
Acceptance Tests
Specifications, KPPs
All Requirements Verified
Validation Tests for
Closed Loop Control
System
Closed Loop Control
System
Part Properties Verified
Sensor Signals
Sensor Requirements
Validation Tests for
Sensor Systems for InProcess Tracking
Sensor Systems for InProcess Tracking
Material Microstructure Requirements
Processing Parameters Valid Ranges
System of ICME/ Physics
Based Tools
Architecture Selection
Microstructure Verified
Validation Tests for ICME/
Physics Based Tools
Compatibility Verified
System Architecture, Machine Interface
and Management Algorithm