Alcoa Additive Manufacturing and Ampliforge TM Process Development

Additive Manufacturing processes have the potential to transform metallic structures by reducing fabrication time and complexity while improving recovery from expensive starting materials.  However, it is not enough to simply produce a specific geometry with a specific composition.  The resultant part has to have sufficient integrity, performance characteristics, and repeatable microstructure to benefit the finished vehicle and be fully qualified for service.  Incorporating the new technology into our comprehensive approach to highly sophisticated metallic products and processes, Alcoa is advancing technology for Additive Manufacturing in multiple alloy systems and processes to provide holistic solutions.  In addition to our direct manufacturing of components, the Ampliforge™ process combines additive manufacturing with forging to produce parts that meet the most stringent specification and integrity requirements while reducing costs for near-net geometries.  As part of our complete AM Flow Path, Alcoa is implementing feedstock capability that will supplement our existing capability to produce Al, Ti, Ni and Co-based materials and optimize the feedstock for additive processes.  This presentation will provide an overview of Alcoa’s additive manufacturing capabilities, examples of AM and Ampliforge™ components, and potential applications.