Additive Manufacturing and the Ampliforge Process for Large Aerospace Components

Arconic is developing high deposition rate (HDR) additive manufacturing processes for aerospace structural components. These components are larger than what can be produced using the typical powder bed AM processes. HDR approaches enable large preforms to be manufactured which have the potential to reduce the cost of structural Ti-6Al-4V components, compared to conventional subtractive methods using thick plates and forgings. This presentation will cover the development of Arconic’s electron beam wire feed capabilities for production of AM preforms for machining. Arconic is also using these preforms for the Ampliforge™ process, which can reduce the cost of forged Ti-6Al-4V components by combining the production advantages of HDR AM with advanced forging technology to achieve a wrought product. Technical developments, materials properties and example business cases will be presented for both HDR AM and Ampliforge™ approaches.