A Novel and Consistent Approach for Evaluating Multiple Machine Platforms in Ti6Al4V Laser Powder Bed Fusion

In order to optimally react to advances in technology and process maturation, the aerospace industry must develop a diversified and competitive additive manufacturing supply chain. A crucial step in remaining competitive is the ability to efficiently evaluate and implement OEM machine design improvements. Targeted future investment into these technologies has the potential to ensure more consistent manufacturing of parts, reduce costs through higher build chamber utilization, and increase desirable material properties.

Due to the diversity that exists between OEM additive machine models in their approach to gas flow, recoating strategy, laser configuration, chamber size, powder handling etc., a consistent methodology was needed to effectively generate comparable data sets between machine models. The methodology developed compares the reliability, consistency, and repeatability of the additive manufacturing process, foundational principles of aerospace quality manufacturing processes. With this new methodology, Boeing is therefore able to directly evaluate the performance of alternative machines available on the market.

In this presentation, both the methods and results of the evaluation of 3 different machine models in Laser Powder Bed Fusion using Ti6Al4V are reviewed, including both the static tensile and high cycle fatigue testing.

In summary, this new methodology is effective in evaluation of new machine advancements and in informing a company’s internal and external sourcing decisions. The data gathered from this methodology could also be used to identify gaps in machine capability and to guide machine OEM development efforts in addressing the rigorous process stability and consistency requirements of the aerospace industry.