Development of Materials for Metallic Direct Digital Manufacturing Navy SBIR FY2012.2 Sol No.: Navy SBIR FY2012.2 Topic No.: N122-123 Topic Title: Development of Materials for Metallic Direct Digital Manufacturing Proposal No.: N122-123-0472 Firm: Keystone Synergistic Enterprises, Inc. 664 NW Enterprise Drive Suite 118 Port Saint Lucie, Florida 34986-2296 Contact: Raymond Walker Phone: (772) 343-7575 Web Site: www.keystonehq.com Abstract: Metallic Direct Digital Manufacturing (MDDM), is based on layer-by-layer metal deposition and has been developed to a sufficient state of manufacturing readiness where production applications have emerged in niche industrial sectors. DDM processes in general require the use of raw materials that are either powdered metal or weld wire, both sources having been developed long before DDM processes emerged. Materials specifically designed for AM/DDM process have not been developed in the metals supply base. Keystone Synergistic Enterprises, Inc. is proposing to develop a raw material chemistry and condition specification beginning with Ti-6Al-4V alloy, tailored to DDM processes, and consistent with aerospace quality standards. In Phase I this process will be started with the generation of a draft specification for DDM Ti-6-4 raw material. From the Ti-6-4 foundation, Keystone will define the next high priority alloys for aerospace, nickel superalloys, high-strength aluminum, high-strength steel, and magnesium alloys. Benefits: The impact of developing a tailored, low-cost raw material for MDDM processes will be a breakthrough event for this high-cost technology. Today's use of metal deposition is at best, niche constrained, such as an alternative to very high buy-to-fly forgings. Standardized raw materials will help reduce the qualification time and cost for companies interested in applying DDM methods. With lower cost raw materials, Digital Direct Manufacturing can generate a shaped metal form that is 30% to 50% less than traditional forgings and in less than 40% of the lead time, offering dramatic reductions in raw material and rough machining operations, supporting a competitive edge to US companies competing in global markets for metallic product. Across the industry, millions of pounds of metal could be saved annually with the cascading effect of lower energy consumption, less waste streams from machining, and clearly lower cost metal product. Return