Aluminum Alloy Development and Use in Additive Manufacturing Process Design for Drive System Gear Boxes
Navy SBIR FY2014.1


Sol No.: Navy SBIR FY2014.1
Topic No.: N141-062
Topic Title: Aluminum Alloy Development and Use in Additive Manufacturing Process Design for Drive System Gear Boxes
Proposal No.: N141-062-0417
Firm: QuesTek Innovations LLC
1820 Ridge Avenue
Evanston, Illinois 60201-3621
Contact: Jason Sebastian
Phone: (847) 425-8227
Web Site: www.questek.com
Abstract: In this Phase I SBIR program, QuesTek Innovations, a leader in the field of integrated computational materials engineering (ICME), proposes to design and develop novel aluminum alloys specifically optimized for the unique processing conditions and challenges of Additive Manufacturing processing. QuesTek is uniquely suited to rapidly designing new aluminum alloys specifically optimized for AM processing using its advanced Materials by Designr stage-gate alloy development process, which is based upon computationally-implemented mechanistic models to predict process-structure and structure-property relationships. Engineers at Bell Helicopter have expressed direct interest in the development of new Al-based alloys for AM, and will act as the voice-of-the-customer to define material property objectives and processing constraints for cast helicopter drive system gear box components. Technical feasibility will be demonstrated in Phase I using pilot-scale powder production (Valimet, Inc.) and leveraging the DMLS production facilities and expertise of manufacturing partner Harvest Technologies (a leader in DMLS-based AM technology). QuesTek's partnership provides a close partnership between material designer (QuesTek), AM manufacturer (Harvest) and OEM user (Bell). Material will be evaluated for microstructure, homogeneity and key mechanical properties (particularly strength, ductility and modulus) to demonstrate the ease of processing of the optimized chemistry and feasibility in achieving target properties.
Benefits: The proposed program is to develop novel aluminum alloys specifically optimized for the unique processing conditions and challenges of Additive Manufacturing (AM) processing. AM processing provides many unique benefits to manufacturing by allowing the production of net-shape complex components without the need for casting molds and tooling, forging, or machining, offering the potential for reduced cost and lead time in producing complex cast components. The helicopter market is very sizable, and cast drive system components demand high performance from complex part designs. The current landscape of aluminum alloy tailored to the unique processing conditions of AM operations is severely limited, leaving component designers interested in adopting AM with little flexibility in their designs. A successful alloy design and development of aluminum alloy specifically tailored to AM processing following ICME protocol will provide the project stakeholders (the Navy and helicopter OEMs) with considerable cost savings and greater freedom in component design.

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