Large Scale Forging Replacement by MELD Additive Manufacturing – Enabled by Slicing Software, Process Parameter Development, and New Machine Hardware

Large forgings and structural components in the aerospace industry can have long lead times. Additionally, design changes to a component can cause delays and increase the overall cost of a project. One key advantage that additive manufacturing has over forgings is the ease of customization. Design changes can often be made on each new print without greatly affecting lead times and cost. This is beneficial to both production part manufacturing and prototyping. MELD, a solid-state additive manufacturing process capable of printing a wide range of materials, can operate in an open-air atmosphere. Open-air printing of aluminum alloys provides the opportunity to lift certain restrictions, such as a restricted build volume, that other melt-based additive manufacturing processes have.

Al-6061 is a common alloy used in the aerospace industry for a wide range of applications. MELD process parameter development of 6061 will be presented, along with the material properties and microstructure for both the as-printed state and the T6 heat treated temper. Slicing software and new advances in machine hardware, such as continuous solid feed, have enabled the MELD process to quickly produce large scale structural components from 6061 and other aluminum alloys. A prime example of this will be shared here. These advancements have enabled engineers and companies to quickly iterate on large scale designs to test fit, form, and function, and produce final parts, without the need to call a forging house.