Large Scale Metal AM - New Developments

The aim of this presentation is to compare and contrast the available techniques and their applicability to both aerospace and space structure in terms of typical deposition rate, microstructure and broad cost structure, both in terms of equipment and in typical applications of interest.

The rapid pace of development of additive manufacturing in aerospace and space is occurring on all fronts necessary to take an emerging suite of AM technologies into the world of manufacturing engineered products for demanding applications – form, fit, and function.  For smaller, intricate parts, the powder bed processes using laser and electron beam are clear choices, with their own trajectory of development qualification, and production implementation.  However, for large structure, alternative processes with higher deposition rate are strong candidates, with the prerequisite requirements for all mechanical and other properties to be met.  This is leading to development work in EBAM, laser with wire, and even arc welding, (referred to collectively by ASTM F42 definition as DED processes).  Arc welding is ubiquitous, and a strong supply chain can be developed.  laser blown powder offers an opportunity for large parts as well.  Required performance at lower cost is the paradigm, vying with the very well established baseline of subtractive techniques, themselves being developed to reduce cost through higher performance.  Opportunities for increased design freedom and lightweighting for increased performance in aerospace and increased payload along with lower launch cost in space vehicles are strong business drivers.