J. R. Wooten, CalRAM, Inc, Simi Valley, CA; P. Yavari, C. Uwate, Northrop Grumman, El Segundo, CA
Layer building technologies offer the potential to reduce cost, shorten delivery time, minimize inventory and increase design flexibility for the manufacture of functional hardware. Although these technologies have been used for several years to produce visualization models and make prototype components, the use of these processes to produce hardware that meets design requirements is just beginning to be realized. The insertion of a new technology requires a significant commitment in terms of developing a materials database to generate design data as well as being able to guarantee the quality of the material is capable of meeting these requirements. The Northrop Grumman Corporation (NGC) and CalRAM, Inc. have been exploring the potential to insert electron beam melted (EBM) Ti-6Al-4V for components that have been previously fabricated by conventional fabrication processes. This paper will describe the EBM process, present the material performance, discuss design requirements for candidate parts and show the quality requirements that are needed to insert the EBM process for the production of flight hardware. A discussion of failure modes will be included. A case study will be presented for a component, the Warm Air Mixer, for the Navy Unmanned Combat Aerial Surveillance (UCAS) which has been manufactured from EBM Ti-6Al-4V.
Summary: Layer building technologies offer the potential to reduce cost, shorten delivery time, minimize inventory and increase design flexibility for the manufacture of functional hardware. Although these technologies have been used for several years to produce visualization models and make prototype components, the use of these processes to produce hardware that meets design requirements is just beginning to be realized. The insertion of a new technology requires a significant commitment in terms of developing a materials database to generate design data as well as being able to guarantee the quality of the material is capable of meeting these requirements. The Northrop Grumman Corporation (NGC) and CalRAM, Inc. have been exploring the potential to insert electron beam melted (EBM) Ti-6Al-4V for components that have been previously fabricated by conventional fabrication processes. This paper will describe the EBM process, present the material performance, discuss design requirements for candidate parts and show the quality requirements that are needed to insert the EBM process for the production of flight hardware. A discussion of failure modes will be included. A case study will be presented for a component, the Warm Air Mixer, for the Navy Unmanned Combat Aerial Surveillance (UCAS) which has been manufactured from EBM Ti-6Al-4V.
