REDAC Subcommittee on Aircraft Safety 9 September 2015 Rollie E Dutton Mary E Kinsella AFRLRXM Air Force Research Laboratory Distribution A Cleared for Public Release Case No 88ABW20152477 19 May 2015 ID: 1047572
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1. The Air Force Qualification Pathway and its Challenges for AMREDAC Subcommittee on Aircraft Safety 9 September 2015Rollie E. Dutton, Mary E. KinsellaAFRL/RXMAir Force Research LaboratoryDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
2. Large Forgings (Unitization)Additive Manufacturing19 ft x 4 ft x 4 ftStructural Complexity isIncreasing“Advanced manufacturing technologies are out-pacing structural analysis capabilities”
3. …using various materials.MetalsPolymersEncompasses many process types…Powder Bed FusionDirected Energy DepositionMaterial ExtrusionVat Photopolymerization…vs. subtracting material from a larger form, e.g., machining.Build a part by adding material layer by layer from a CAD file…emeraldinsight.comAdditive Manufacturing OverviewMaterial JettingBinder JettingSheet Laminationctemag.comCompositesCeramicsDistribution A: Cleared for Public Release Case Number 88ABW-2015-2419 15 May 2015
4. Powder Bed Fusionnature.com/scientificamerican/journal/axisproto.comsolidconcepts.comdirectmetallasersintering.netProcess SchematicEquipmentWork in ProcessFinished PartsAn additive manufacturing process in which thermal energy selectively fuses regions of a powder bedDezeen.com
5. Directed Energy Depositionrpmandassociates.comProcess Schematictms.orgSandia.govFinished PartsSciaky.comEquipmentWork in ProcessAn additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being depositedCourtesy: Lockheed MartinDistribution A: Cleared for Public Release Case Number 88ABW-2015-2419 15 May 2015
6. AFRL/RX Metallic Additive Manufacturing HistorySignificant AdditiveAerospace EventsMaterials and Manufacturing Directorate Critical ActivityOPTOMECAEROMETAcademic EngagementEOSF-15 Pylon Rib SubstitutionMAI – AMPowder BedComplex HXsF35 FlaperonSparApplication “Rules”DevelopedM&P In-house R&D7 publications:M&P of Ti LAMObsolete Parts: Form/Fit ModelsMAI DepositionOn Engine CasesOEM Teamingto Address Gaps~$30M InvestmentOpen ManufacturingProgram19801985199019952000200520102015Gas Turbine Fuel NozzlesStereo Lithography & Selective Laser Sintering Invented
7. F-15 Pylon Rib Insertion Success StoryResults: - Additive Substitution Certified for use in Structural Application! - Parts Manufactured and Qualified although cost 3-5X over forging cost - Prior to Insertion on AC, Aluminum Industry Provided Forgings - Forging cost reduced due to competitionIssue: - Pylon Rib, 7075 Al Forging, Corrosion Fatigue Cracking - Decision to move to Ti 6-4 forging- Long lead time for Ti forging ~1 yearSolution: -Replace with Ti 6Al-4V Additive - Quality concerns lessened due to high margin for Ti in this application.RX Role: -Provided Technical Leadership to Acquisition -Executed Technology Demonstration Project -Worked Attachment Issues (bushings, fasteners, etc...)Distribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
8. Process Qualification RequirementsQualification of processes and certification of components used on AF systems requires that components meet or exceed the following criteria, regardless of the manufacturing process used:Airframe or engine specificationsAF system requirements and structural integrity policies/proceduresDrawing complianceConformance to material specificationsJustifiable and attractive business caseAll manufacturing processes (including AM) also must demonstrate:Stability – no suitable public specs exist, very few OEM-based, mostly internalProducibility – most AM vendors/OEMs have not demonstrated reproducibilityCharacterized Mechanical and Physical Properties – limited non-proprietary dataPredictability of Performance – insufficient component-level testingSupportability – undefined in-field inspection and/or repair processesChallenges for qualifying AM processes and certifying AM components arise due to a lack of reproducibility and a lack of a governing process specification.Distribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
9. Qualification Pathway:New Materials and ProcessesStabilityProducibilityPerformance PredictabilitySupportabilityComponentConformance/ EquivalencyProcess QualificationPart QualificationDesignAllowablesValidated Quality AssuranceStatistical Mech. Property DatabasesInspectionProtocolsEngineeringDesign AnalysisPart ZoningProof Test ValidationBusiness CaseAnalysisOn-Wing Inspection ValidationRepair Options/ Focused InspectionProcess DevelopmentProcess OptimizationMat’l Sensitivity to Process VariationEffect of DefectsPost-Processing & Residual Stress ManagementDemonstrated Process Controls and Repeatability Dr. Lincoln’s RequirementsMaterial &ProcessSpecsFatigue & FractureA-Basis99/95S-Basis90/50B-Basis90/95Damage TolerantSafe LifeFail SafeStrength RequirementsCharacterization of Mechanical and Physical PropertiesDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
10. Why AM Implementation Is a ChallengeStructures Bulletin: Substitution with AMNOT RECOMMENDED without significant testing and AFRL/RX supportBulletin to be appended with position paper on critical AM considerationsConsiderations for Implementation of AMDemonstrated Process ControlsNondestructive Evaluation & Quality AssurancePost-Deposit Processing & Residual Stress ManagementStatistically-Based Mechanical Property DatabaseHow to statistically ensure material integrity for design withcontinually-changing, local processing environment with changes in geometry and process parameters (similar to welding)lack of constrained process controlsstochastic formation of difficult-to-inspect weld-type defectspost-deposit distortion and residual stress undefined post-processing requirements, lack of POD for NDIDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
11. PartDesignPrintSystemAdditive Manufacturing:Challenges to AF ImplementationComponent DesignTool Integration, CAD Validation& ControlFeedstock Control & Qualified Materials OptionsProcess Design, Optimization, Control & MonitoringQuality Assurance & Post-Processing Req’mt DefinitionComponent CertificationValue Proposition,Accurate Cost ModelsFielded System Risk MgmtIntegrated, Risk-BasedQualification MethodologyDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
12. AM Challenges to AF Implementation:DesignMechanical Design ApproachProcess regularly produces what would be considered defects in conventional processes: porosity and lack of fusionAnisotropic & variable mechanical propertiesDesign is not “unconstrained by manufacturing”There are “AM design rules” that are different than conventional manufacturing design rulesUndefined AM LimitationsMin/Max Wall ThicknessesComplexityWall Pitch, Radii “Overhangs”, “Ceilings”Support Structures2543software.materialise.comDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
13. AM Challenges to AF Implementation:PrintAM ProcessingRange of process parametersCurrent, speed, hatch spacingLaser/beam focus and offsetContour, passes, turning pointEmpirical corrections, scaling factorsSurface temperature, environmentQualitative calibration proceduresrecalibration frequency, inconsistent maintenance proceduresPowder recyclability proceduresPseudo-Empirical Black Boxes to control processManufacturing variability is unknown & a major consideration:two parts, same fixed process, different structureDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
14. AM Challenges to AF Implementation:PrintAM Powder Bed FusionExamples of process-induced defectsAdd some more here,videos and images,Descriptions ofprocesses Distribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
15. AM Challenges to AF Implementation:Part InspectionSurface FinishAs-deposited and porous surface finish reduces inspection effectivenessFluorescent Penetrant: High background fluorescence and false positivesUltrasonics: Poor coupling of sound into substrate from coarse and non-planar surfaces.Micro/Macro StructureEBAM Ti-6Al-4V Beta Anneal heat treat results in coarse and columnar microstructures.Limits effective inspection depth to < 1 inch to detect 3/64” FBHResult: process layup & post-deposit sequence re-design requiredComplex GeometriesLimits inspectability of 100% part volumeComputed Tomography of Powder Bed, Ni and TiX-ray scattering challenges – thick vs. thin wall challengesNeed technique qualification and flaw characterization tools/algorithms High Propensity for Flaw GenerationDistributed/linear porosity and incomplete fusionDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
16. AM Challenges to AF Implementation:SystemCertificationProof testingViable means to assure material quality with sufficient design analysisOnly for suitable applications/componentsComponent performance equivalency to material dataGenerally, lack activity in this areaVery thin walls & complex geometries limit ability to excise test specimensHow to certify componentCertify by similarity? Similar to what?Certify by analysis? With what tools?Sub-scale testing? How to justify?Full scale test? Expensive.In-Field Inspectionsunknown inspection toolspost-processing affects inspectabilityincreased inspection burden?Distribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
17. AM is a Ready-for-Use Technologyfor Some ApplicationsThe big picture: Improve existing processes by implementing hard masking.How do we get from drawing/concept to manufactured component in the least amount of time?Gearbox painting Mask profilePlasma sprayShadow maskShot peeningMask fixture17A fundamental change in how fixtures are designed and how we do repairs (repair approval) must precede this added technology!Distribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
18. Strategic vs Tactical PlanningFactorsTime PeriodReversibility Scope Affected AreasGoals Strategic PlanningLongHarder Broad Many Functional AreasMeans & Ends Tactical PlanningShortEasier Narrow Few Functional AreasMeans “Plans are nothing; planning is everything.” - Dwight Eisenhower
19. AFRL Additive Manufacturing StrategyDevelop Risk-Quantification Tool for Substitution and Implementation of AM technologies in AF SystemsConduct Targeted Research to Inform the Qualification of Additive Materials and ProcessesProcess monitoring and sensingNDE and material characterizationAM-tailored material developmentComponent demonstrationAdvance AM Capabilities via Modeling & SimulationProcess simulation for design & controlVerification & Validation for qualificationProcess-structure-property relationshipsDevelop digital thread for AM componentsDistribution A: Cleared for Public Release Case No. 88ABW-2015-2477 19 May 2015
20. Strategy for Insertion of Advanced Manufacturing Technologies(not just AM!)Establish Rules to Quantify RiskDevelop Decision Matrix and GuidelinesComponent-Specific Attributes Propagated through Decision TreeSystematically Identify Risk & NeedsScientifically-Informed Engineering JudgmentExtendable Framework Example Guideline QuestionsAccess to Designer’s Intent?Static or Dynamic Loading?Current Material & Process?Established Processing Parameters?Inspection Requirements?Component Cost, Lead Time?Establish rules and develop tools for systematic and evolutionary adoption of rapid manufacturing technologies
21. Closing ThoughtsThis is a unique moment in time to Change the Paradigm for the qualification of new Materials & ProcessesStrategic Planning is essential:DefinitionsFocusRoles & ResponsibilitiesRequirementsStandards“A Vision without a plan is a hallucination.” - Diran Apelian
22. Elements Required for Real ChangeCleared for Public Release 88ABW-2012-5158Courtesy Bob Bucci
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24. Additive Manufacturing IPTConceptCollaboration/ National Awareness and Outreach TeamFocused Research and Transition Team Structural Problem Set #1Structural Problem Set #2Structural Problem Set #3Functional Problem Set #3Functional Problem Set #2Functional Problem Set #1Focused Research and Transition Team Core TeamIPT Strategic Development & Long-Term Research “seeding”Structural AM Lead Coordination & Collaboration LeadKnowledge ExchangeIntegrated Problem:Multifunctionally-Embedded StructuresFunctional AM Lead Distribution A: Cleared for Public Release Case Number 88ABW-2015-2419 15 May 2015
25. A Defense-wide Manufacturing S&T team-led, Multi-agency collaboration between industry, government and universities Public-private partnershipShared facilities open to industryEspecially attractive to small businessesEnabling technology transition and commercializationAddressing Technology Readiness Level (TRL) / Manufacturing Readiness Level (MRL) 4-7 Bridge the gap in Manufacturing InnovationEducational outreach and workforce developmentA Model for Subsequent Manufacturing Innovation InstitutesDistribution A: Cleared for Public Release Case Number 88ABW-2015-2419 15 May 2015