K. M. B. Taminger, NASA Langley Research Center, Hampton, VA
NASA Langley is attempting to catalyze a national capability to build metallic industrial components without the huge waste of current large scale milling process. Electron Beam Freeform Fabrication (EBF3) is an additive metal process using an electron beam, wire feed, and computer controls to build near net shaped components, either by addition of details onto a simplified preform or by fabricating the entire component. The EBF3 process can be used to reduce high buy-to-fly ratios (12:1 to 20:1 are not uncommon for some components) down to less than 5:1, offering significant savings in resources such as raw materials, energy consumed, fewer chemicals (cutting fluids), and lead time as compared with current practices of machining large volumes of chips out of a solid billet. Researchers at NASA Langley have led research and development of the EBF3 process since 2002. NASA’s goals in developing this technology include process controls for unattended operation and repeatability, certification of EBF3 processed materials for space hardware applications, demonstration of space-qualified hardware to support long duration human exploration missions, and development of tailored structures with integrated multifunctionality for aerostructural applications. Industrial applications of the EBF3 process include the production of replacement components for aging aircraft as well as reducing cost, lead time, and environmental responsibility for production of new aircraft components more efficiently than hogging out components from oversized billets of metal. An innovative alliance between NASA and industry has recently been formed to accelerate the certification and standards process and stimulate the growth of a competitive supply chain for providing commercial EBF3 services within the next 4 to 5 years. This talk will discuss the alliance technical goals and progress towards those goals as they relate to inserting the EBF3 process into the industrial sector.
Summary: Technical summary of alliance formed to develop EBF3 process for obtaining FAA and military certification and stimulating growth of a new manufacturing supply web. Presentation will include discussion of the alliance members and highlight activities being pursued to achieve the goals of certification and supply web stimulation.
