TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-265

OBJECTIVE: Develop the methodology, models, and analytical tools, required to rapidly and inexpensively qualify metallic aircraft components produced using DDM. Reduce the time and cost associated with individually qualifying aircraft parts by developing a streamlined approach to the certification wide variety of metallic DDM parts.

DESCRIPTION: Direct digital manufacturing (DDM) is very attractive because it reduces part cost, reduces the energy content of parts, and increases the operational availability of navy aircraft. Part acquisition time can be reduced from 6-12 months for long-lead time items or out-of production part to less than 24 hours. Energy and machining cost are significantly reduced because no tooling is required to produce DDM parts, and part machining is virtually eliminated. Consider that the buy-to-fly ration on a conventionally produced titanium part is 10 to 20:1, whereas for DDM, the buy-to-fly ratio approaches 1:1.

However, in order to fully realize these benefits, DDM technology needs to be certified for the fabrication of a wide range of metallic parts having diverse geometries. Presently, in order to ensure air worthiness, each type of part must pass a lengthy and costly certification process [1]. This significantly impacts the Navy�s ability to use DDM to produce parts-on-demand.

It is proposed that a new innovative method be developed for part certification using a heuristic and adaptive approach combined with non-destructive inspection, and limited mechanical property tests. It is envisioned that an aircraft component to be composed of several building blocks of simple 3-dimensional geometric shapes, such as cuboids, cones, spheres, prisms and so on. These representative geometric elements of a component could be fabricated using DDM, analyzed and tested for defects and mechanical properties. The statistics of test results of the building blocks could be fused in a qualification algorithm and used to establish the basis for qualifying additional parts.

PHASE I: Develop and demonstrate the feasibility of a rapid and low cost approach to metallic DDM aircraft part qualification.

PHASE II: Develop and demonstrate a prototype (the methodology, models, and qualification algorithm) required to rapidly qualify metallic DDM components of varying shape and size.

PHASE III: These tools and methods could be used to qualify a broad range of metallic DDM parts for military and civilian applications.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The qualification algorithm along with the database of test results for the building blocks of various geometric shapes and sizes will be a marketable tool. It will be tied to the particular DDM process used and can be marketed to all private and public sector industries for rapid qualification of parts.

REFERENCES:
1. William Frazier, Don Polakovics, and Wayne Koegel, "Qualification of Metallic Materials and Structures for Aerospace Applications," JOM. March 2001.

KEYWORDS: Direct Digital Manufacturing, Qualification, Prototype, Certification, Heuristic, Adaptive, NDI

** TOPIC AUTHOR (TPOC) **

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