Large-Scale Hybrid Polymetal Manufacturing Using Graded and Tailored Alloys
Abstract
In the face of increasingly agile U.S. adversaries, the Department of Defense (DoD) has identified additive manufacturing (AM) as a means for in-theatre production of higherperformance designs. Current AM build practices have focused on powder bed fusion (PBF) processes that are hard to scale in size and generally limited to the choice of a single alloy. These limitations constrain 1) the size and complexity of components that can be built by AM and 2) the ability to optimize part performance using AM. Directed energy deposition (DED) processes have been used to produce multi-meter scale mechanical components composed of graded alloys, designed to avoid deleterious phases in the regions between functional microstructures in multi-metal (i.e. polymetal) composites. Further, new DED head designs are making it easier to produce tailored alloys, i.e., novel composite alloys designed to satisfy part functionality. While robotic DED is scalable in size and capable of polymetal fabrication, it results in rough, near-net-shape parts requiring post-process machining. For components containing embedded features, post machining is not possible requiring hybrid additive and subtractive processing. The overall objective of this research program is to demonstrate for the Department of Navy the large-scale hybrid polymetal manufacturing of higher performance “point of need” mechanical components using DED. One goal of the proposed program will be to demonstrate the fabrication of large, higher performance impellers and heat exchangers. A second goal will be to simultaneously advance the mechanical design methodology, materials development methodology, process development and in-process control necessary to enhance the performance of impellers and heat exchangers. Oregon State University (OSU) and the University of Tennessee, Knoxville (UTK) will partner to meet these goals. OSU will build on recent successes in using PBF processes to produce net shape heat exchangers composed of hardto- build metal matrix composites and other tailored alloys. UTK will leverage its experience in developing large-scale wire+arc DED processes, capable of non-gravity aligned fabrication, in partnership with Oak Ridge National Laboratory’s Manufacturing Demonstration Facility. This program team is capable of integrating advancements across mechanical part design, materials design and hybrid DED process development necessary to advance higher performance heat exchangers and impellers for the Department of Navy.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Oct 19, 2020
- Source ID
- N000142012836
Entities
People
- Brian Paul
Organizations
- Office of Naval Research
- Oregon State University
- United States Navy