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.: N161-071-0562 Firm: ALPHA STAR 5150 E. PACIFIC COAST HWY SUITE # 650 LONG BEACH, California 90804 Contact: FRANK ABDI Phone: (562) 961-7827 Web Site: http://www.alphastarcorp.com Abstract: AlphaSTAR Corporation (ASC) proposes an improved thermally-monitored-controlled Selective Laser Melting (SLM) additive manufacturing process, with improved mechanical properties associated with Titanium and /or Steel. We will customize/upgrade our award winning GENOA 3D-print software capable of simulating the additive manufacturing to conformal heat exchanger, by predicting thermal history and manufactured properties and thereby providing a methodology to optimize the process and lead to certification. ASC will utilize GENOA software to predict bulk thermal response, solidification, deflection, residual stress, damage initiation, crack propagation, and post-fabrication mechanical performance of simple geometries fabricated via SLM. Real test data will be collected in order to accelerate material qualification and numerical model validation. ASC will exploit thermal monitoring and process control to determine relationship between SLM process parameters (laser power, laser beam diameter, scanning speed, hatch space, absorption rate, etc.) and thermal history in order to reduce the occurrence of porosity and residual stress formation during the additive process. Working with subject area experts. ASC will undertake component-level modeling and simulation optimized fabrication, based on multi-objective SLM parameter optimization. Utilizing gained relationships between process parameters, thermal history and microstructure, parameter inputs required for fabrication of components with tailored mechanical properties will be determined. Benefits: The integration of GENOA software with SLM manufacturing would represent a revolution in powder metal fabrication. The SLM process, in which successive layers are created by selectively fusing metallic powder using a high-energy laser beam, could be tuned with the help of simulation to additively manufacture components with less anisotropy and more precision. As such, the end-user, empowered ASC simulation technology would be able to `design for SLM' by knowing post-manufacture part stresses during service and predicting process-inherent residual stresses, microstructure and defects. Consequently, the manufacturing lead time for highly-customized and certified parts would be reduced, which would allow on-demand manufacture of components with tailored mechanical, thermal properties, such as those required for a conformal heat exchanger and those required for a Naval and Marine application. Ultimately, the net effect would be greater efficiency, increased utilization and adaptation. More importantly better quality parts would be more readily available at reduced costs and ready for certification. Return