B. H. Walker, R. M. Walker, Keystone Synergistic Enterprises, Inc., Port St. Lucie, FL
Keystone Synergistic Enterprises, Inc. and their business partner Acceleron, Inc. have recently completed an Air Force sponsored Phase II SBIR program demonstrating advances in processing of IN 718 using wire feed, electron beam free form fabrication (EBFFF) methods. Extensive process characterization was utilized to establish a direct correlation of process parameters with material microstructure, mechanical properties and quality. Both monolithic and dual alloy, complex gas turbine engine cases were produced with near-parent-metal mechanical properties and quality meeting aerospace requirements. Empirically validated economic process modeling verified components can be affordably produced by EBFFF using either direct or additive manufacturing methods. Keystone will present detailed results from this program and their efforts to date to bring this important technology to production readiness and offer EBFFF manufacturing services to industry.
Summary: Keystone Synergistic Enterprises, Inc. and their business partner Acceleron, Inc. have recently completed an Air Force sponsored Phase II SBIR program demonstrating advances in processing of IN 718 using wire feed, electron beam free form fabrication (EBFFF) methods. Extensive process characterization was utilized to establish a direct correlation of process parameters with material microstructure, mechanical properties and quality. Both monolithic and dual alloy, complex gas turbine engine cases were produced with near-parent-metal mechanical properties and quality meeting aerospace requirements. Empirically validated economic process modeling verified components can be affordably produced by EBFFF using either direct or additive manufacturing methods. Keystone will present detailed results from this program and their efforts to date to bring this important technology to production readiness and offer EBFFF manufacturing services to industry.
