| About this Abstract |
| Meeting |
2023 AWS Professional Program
|
| Symposium
|
2023 AWS Professional Program
|
| Presentation Title |
Geometrical Feature Development for Multi-Process DED of Aerospace Structures using Ultra High Strength Steel (UHSS) |
| Author(s) |
James McNeil, Dennis Harwig, Stacey Smith, Dean Langenkamp, Jake Hay, Nikolas M. Vega Michalak, Boian Alexandrov, Philip Flater |
| On-Site Speaker (Planned) |
James McNeil |
| Abstract Scope |
I. Introduction
Large Scale Additive Manufacturing of Metals (LSAMM) has been gaining traction in industry for use cases where materials that can be difficult to source or can more easily be deposited from traditionally available wire feedstock. For applications with unique materials, special care must be taken to develop the appropriate process parameter to microstructure property relationships, while also maintaining build geometry quality and functionality. A recent project focused on using arc & laser DED to produce DED geometries from the Ultra High Strength Steel (UHSS) AF9628. The geometries produced from this system were developed in conjunction with microstructure/property models produced through work at the Ohio State University Welding Engineering Laboratory and applied onto the large-scale multi-process robotic gantry system at EWI. The intention of the work was to show how LSAMM using both additive & subtractive techniques can be used to produce geometrical features that meet near net shape needs while maintaining microstructure and property requirements. The DED of UHSS material with a focus on maintain geometric fidelity is important towards driving market adoption of large-scale hybrid manufacturing technology for future applications with unique materials & geometries.
II. Experimental Procedures
Initial development work centered around establishing microstructure to property relationships with single pass and multi-pass mini builds with varying interpass temperature requirements. These mini builds were used to develop thin feature and bulk feature deposition strategies for the material. Coupled with evaluation and microstructure/property modeling from the Ohio State Welding Engineering Laboratory, these parameters will be used to select ideal deposition parameters for producing builds. After the process properties were established, geometrical features were produced using digital twins and build models in PowerMill for the system. As well as arc and laser DED build models, subtractive techniques for improving near net shape in-situ and/or post-deposition will be evaluated. The workflow driving use of hybrid techniques can be dictated from the near net shape and material requirements. A combination of additive and subtractive techniques will be identified that allow the UHSS material properties to be maintained while improving throughput efficiency for reaching near net shape and fine feature resolution for this application.
III. Results & Discussion
Results of this work will be focused primarily on the geometrical performance of the hybrid approach when it comes to producing geometry. Part scans of the material are used to evaluate the performance of additive and subtractive techniques, as well as the workflow for producing large scale part features. A particular focus will be on how workflow and ideal process selection may not be possible given build geometry requirements and material property requirements. Deposition process techniques related to minimum & maximum interpass temperature must be evaluated for deposition throughput and accuracy. Discussion on how near net shape geometry can be produced more effectively as well as a discussion on process improvements to improve or meet material property requirements will also be discussed.
IV. Conclusion
For this work, a variety of AF9638 arc & laser DED geometries are produced using a large-scale multi-process robotic gantry system at EWI. The geometries will be produced using best practices developed through digital twin and model workflows, as well as informed on process-property performance through efforts of modeling and evaluation of mini-builds from the Ohio State University Welding Engineering Laboratory. The produced geometries have a variety of interesting features produced using both additive and subtractive methods with a focus on full workflow model integration and near net shape evaluation. These features will be evaluated using part geometric scans as well as NDE and NDT methods to confirm build quality and soundness. The results of this work can be used to inform performance for UHSS DED for future complex geometries as well as identifying future work on process and modeling improvements to produce geometry of UHSS using DED and hybrid manufacturing methods.
V. Keywords
Arc-DED, Laser-DED, Hybrid Manufacturing, Additive Manufacturing, Process Optimization |
| Proceedings Inclusion? |
Undecided |