F. G. Arcella, K. Lyons, D. H. Abbott, AeroMet Corporation, Eden Prairie, MN
The AeroMet Laser Additive Manufacturing (LAM) process will be overviewed with examples. The process has been used to fabricate full scale Ti-6Al-4V aerostructures without molds or dies in as little as 8 weeks. Decision criteria for selection of candidate components for optimal low cost fabrication by LAM will be overviewed. Examples will be shown where digital CAD representations will be converted to solid models, substrates selected, and deposition/substrate tradeoffs evaluated. Approved software driven trajectories from a standard “toolkit” are assembled in pattern sequences to produce the desired machining “preform” geometry using controlled deposition parameters. Control of process, feedstock, structure integrity, and stresses will be overviewed. Post forming CMM, point cloud solid model validation of geometry, heat treatment, machining and inspections will be overviewed. Examples of small lot production by traveler and manufacturing specifications will be presented with demonstration of meeting aerostructures quality standards.