Additive Manufacturing Development of Naval Platform Heat Exchangers Navy SBIR FY2016.1 Sol No.: Navy SBIR FY2016.1 Topic No.: N161-071 Topic Title: Additive Manufacturing Development of Naval Platform Heat Exchangers Proposal No.: N161-071-0573 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201 Contact: Jason Sebastian Phone: (847) 425-8227 Web Site: http://www.questek.com Abstract: In this SBIR program, QuesTek Innovations LLC will apply its computational materials methodology to develop ICME tools that directly address the unique complexity of additive manufacturing (AM) processing. CALPHAD-type modeling along with materials property and process evaluation will be applied to make an intelligent selection of commercial heat exchanger (HX) alloy(s), or composition optimization, suitable for AM. ICME models will be developed to describe materials properties and processing, and the ICME methodology will be applied to assess commercial HX alloys in terms of "AM processablity". A parametric approach will then be used to downselect alloy(s) of interest, followed by test coupon-scale direct metal laser sintering fabrication and characterization. QuesTek will partner with GPI Prototype and Manufacturing Services Inc., who will provide assistance in material procurement, AM process evaluation and test coupon prototyping. Test coupons of selected alloy(s) will be printed and characterized for proof-of-concept while further addressing one of the unique challenges of building HX components; component thinness. The Phase I program will ultimately conclude with an integrated, predictive mechanistic based computational tool to predict alloy processability for powder metal AM processes, and the methodology will be tailored to HX alloys ultimately minimizing defects and improving component reliability. Benefits: There are currently no ICME tools tailored to AM processing. ICME tools are essential components for any microstructural modeling or processing prediction. As such, these new ICME tools would greatly assist in the screening for appropriate HX- and other materials, as well as aid in risk assessment and failure analysis of existing and future alloy systems and components produced by AM. There are direct cost savings in each of these processes for both military and industry. Under this SBIR program, QuesTek will be developing a package of ICME models to optimize the metal additive manufacturing (AM) processes for heat exchangers (HX). There are market needs in both DoD and the private sector: printing alloys optimized for the unique conditions and challenges of AM manufacturing pathways enables a novel process that promises cost savings through reduced component thickness, and therefore overall HX product weight, improved system efficiency and reduced production costs. Return