SOLID STATE ADDITIVE MANUFACTURING of LARGE, COMPLEX METALLIC COMPONENTS USING the MELD PROCESS

MELD Manufacturing has developed a unique friction stir additive manufacturing process, a solid-state technique that can print large metallic parts faster than other additive manufacturing methods. An open atmosphere process, it requires no special chambers or vacuum and uses scalable equipment, with no practical limit to component size. With no melting required, the process can print a wide variety of alloy systems including multi-alloy builds producing near-net shape parts that are fully dense.

The MELD Process has exciting potential for a wide range of industries including aerospace, high performance auto/racing, industrial and defense. Advantages include not only an ability to make new parts, but also to add features and repair damaged parts.

This talk will focus on aluminum and titanium components and their manufacture. We will discuss detailed microstructures and properties for a number of alloys as we have developed alloy- and part-specific techniques for a wide variety of geometries and performance requirements. Much of the talk’s focus will be on directionality in properties comparing X, Y, and Z directions and associated orientations for fracture toughness and corrosion properties.

MELD is unique that the process can directly print high-strength aluminum alloys such as 6061, 7075 and 7050 with mechanical, damage tolerant and corrosion properties similar to conventional wrought products such as forgings while reducing time and cost and producing complex geometries not possible with die forging. We continue to expand the portfolio of aluminum alloys with work in 2xxx and 5xxx alloy systems.

The MELD process is also producing titanium parts, especially Ti-6-4 to reduce material and input and machining cost and time while producing a wrought microstructure with forged properties.

MELD is currently supplying machines and parts. The machines range from enclosed 600 x 1100 mm beds to open 6.5 x 9m beds with gantry-type spindles.