Real-Time AM Process Models Applied to Wire Fed Robotic Pulsed-Arc Processed 4340 Steel Navy STTR FY2015.A Sol No.: Navy STTR FY2015.A Topic No.: N15A-T007 Topic Title: Real-Time AM Process Models Applied to Wire Fed Robotic Pulsed-Arc Processed 4340 Steel Proposal No.: N15A-007-0097 Firm: Keystone Synergistic Enterprises, Inc. 664 NW Enterprise Drive Suite 118 Port Saint Lucie, Florida 34986-2296 Contact: Bryant Walker Phone: (772) 343-7544 Web Site: www.keystonehq.com Abstract: This STTR will focus on demonstrating feasible methods to integrate additive manufacturing (AM) structure, processing, and property-geometry modeling methods that will facilitate the qualification and certification of AM-fabricated 4340 steel alloy parts and enable their rapid deployment. During the Phase I feasibility demonstrations the contractor and Research Institute (RI) will define and develop a concept for innovative real-time process models for AM of 4340 robotic pulsed-arc, wire feed materials. They will demonstrate the feasibility to monitor and model the fabrication process and predict the resulting material micro-structures and mechanical properties of the fabricated materials and conduct an initial structural test to confirm properties of the feature shape. Benefits: Successful completion of this STTR will facilitate the qualification and certification of Additively Manufactured 4340 steel alloy components and enable their rapid deployment. The path for commercialization will be through the application and sale of robotic pulsed-arc systems to DoD and other Federal Agencies, and /or private sector markets. Keystone anticipates the sale of three to four systems per year starting in CY 2017. Keystone will integrate the algorithmic models and in-process monitoring methods successfully developed during this project into the Keystone robotic, pulsed-arc system for commercial sale. They also plan to offer complete, in-process control and monitoring systems adaptable to other types of AM processes as the market matures for this product. Return