Development of 7050 T-74 Aluminum Alloy Alternative for use in Additive Manufacturing (AM) Systems Navy SBIR FY2015.1 Sol No.: Navy SBIR FY2015.1 Topic No.: N151-010 Topic Title: Development of 7050 T-74 Aluminum Alloy Alternative for use in Additive Manufacturing (AM) Systems Proposal No.: N151-010-0569 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201 Contact: Jason Sebastian Phone: (847) 425-8227 Web Site: www.questek.com Abstract: Additive Manufacturing (AM) promises to be an innovative technology that can enable rapid manufacturing of complex parts at greatly reduced cycle time. Application of this technology to the manufacture of aircraft structural components is limited by the lack of high-strength aluminum alloys optimized for AM processing. In this Phase I SBIR program, QuesTek Innovations, a leader in the field of integrated computational materials engineering (ICME), proposes to develop a new class of 7000-series aluminum alloys optimized for AM. QuesTek is uniquely suited to rapidly designing new aluminum alloys for AM using its Materials by Designr stage-gate development process, which is based upon computationally-implemented mechanistic models to predict process-structure and structure-property relationships. QuesTek's alloy design strategy will target an optimization of conventional Al-Zn-based alloys against the characteristic hot tearing susceptibility that currently limits the AM processability of high-strength aluminum alloys (such as 7050-T74). Engineers at Northrop Grumman and Boeing have expressed direct interest in the development of new Al-based alloys for AM, and will act define material property objectives for aircraft structural components. QuesTek is teaming with 3DSIM and LPW Technology to link microstructural prediction to processing variables and accelerate specification development for the new alloy. Technical feasibility will be demonstrated in Phase I using pilot-scale powder production and DMLS processing in partnership with Stratasys Direct Manufacturing. QuesTek's partnership provides a close collaboration between material design, powder development, AM processing, and OEM. Benefits: The proposed program is to develop novel aluminum alloys specifically optimized for the unique processing conditions and challenges of Additive Manufacturing (AM) processing. AM processing provides many unique benefits to manufacturing by allowing the production of net-shape complex components without the need for casting molds and tooling, forging, or machining, offering the potential for reduced cost and lead time in producing complex cast components. The airframe market is very sizable, and such components demand high performance from complex part designs. The current landscape of aluminum alloy tailored to the unique processing conditions of AM operations is severely limited, leaving component designers interested in adopting AM with little flexibility in their designs. A successful alloy design and development of aluminum alloy specifically tailored to AM processing following ICME protocol will provide the project stakeholders (the Navy and aircraft OEMs) with considerable cost savings and greater freedom in component design. Return