Towards rapid qualification of powder-bed laser additively manufactured parts
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Qualification of aerospace components is a long and costly process involving material properties, material specifications, manufacturing process, and design among others. Reducing qualification time and cost while maintaining safety offers a large economic advantage and enables faster response to the market demands. In 2012, DARPA established the Open Manufacturing program, a project to develop an integrated computational materials engineering (ICME) framework aimed at rapid qualification. Rapid qualification requires the integration of several technologies: materials, process, design, models, monitoring and control, non-destructive evaluation (NDE), testing, among others. A probabilistic design approach is adopted in the rapid qualification process to enable the integration of these technologies into a single risk-based function to optimize the design process. This approach directs the efforts to those areas that play the most important roles, potentially reducing specimen testing that will be required to develop material databases and design limits. New tests also will be required to validate and verify the ICME framework and develop a better understanding of the processing-microstructure-property relation and associated variability of the processing conditions. The probabilistic design approach is demonstrated for the rapid qualification of an actual aircraft engine component constructed via the powder-bed additive manufacturing process. This paper summarizes the probabilistic rapid qualification design approach and its application to this novel manufacturing process with the goal of reducing the overall qualification process time by 40 % and qualification process cost by 20 %.
KeywordsRapid qualification Integrated computational materials engineering Uncertainty quantification Process modeling Materials modeling Process monitoring Non-destructive evaluation Verification and validation
This work was performed under the DARPA Open Manufacturing Program entitled “Rapid Low Cost Additive Manufacturing” contract number HR001-12-C-0037 to Honeywell International Inc. The authors acknowledge the financial support and the guidance of the managing panel.
We would also like to acknowledge our colleagues who have helped with different aspects of the program. From Honeywell: J. Neumann, H. Deutchman, B. Baughman, P. Kantzos, M. Kemp, S. Singh, B. Shula., and G. Levesque. From SwRI: J. McFarland. From ESI: N. N’Dri, H.-W. Mindt. From Questek: D. Snyder, G. Olson, J. Sebastien. From Sigma Labs: M. Cola. V. Dave. From Stratonics: T. Wakeman.
This work presented in the manuscript was performed under the DARPA Open Manufacturing Program entitled “Rapid Low Cost Additive Manufacturing” contract number HR001-12-C-0037 to Honeywell International Inc. The manuscript itself was prepared using DARPA funding.
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