Application of ICME to Optimize Processing of State-of-the-art Gear Steels in Additive Manufacturing

Award Information
Agency: Department of Defense
Branch: Army
Contract: W911W6-16-C-0011
Agency Tracking Number: A153-104-0213
Amount: $99,392.96
Phase: Phase I
Program: SBIR
Awards Year: 2016
Solicitation Year: 2015
Solicitation Topic Code: A15-104
Solicitation Number: 2015.3
Small Business Information
1820 Ridge Avenue, Evanston, IL, 60201
DUNS: 088176961
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Jason Sebastian, Ph.D.
 (847) 425-8227
Business Contact
 Voula Colburn
Phone: (847) 425-8215
Research Institution
Additive manufacturing (AM) is a novel process of fabricating components in a layer-by-layer method under the control of computer-aided design (CAD) information, rather than by the traditional use of casting molds and forming dies. Integrated Computational Materials Engineering (ICME) methodologies are effective tools to reconfigure the materials development process and accelerate implementation of new higher performance alloys into demanding applications. QuesTek Innovations, an ICME leader, proposes to develop new LENS Additive Manufacturing techniques and new finite element approaches to characterizing the effect of AM defects on material properties. C64 is a gear steel designed to be an upgrade over X53 via traditional-processing, and serves as a good transition candidate. In Phase I, QuesTek will utilize currently developed ICME tools and models to develop a new gradient deposition technique to produce varying material properties (e.g., in-build carburizing). New finite element techniques will focus on porosity distributions in AM material to statistically determine material properties. QuesTek has support from OEM Bell Helicopter, and will utilize the expertise of Penn State University (AM excellence center) throughout the program. Demonstration of feasibility allows for further optimization, characterization, and wear testing to be accomplished in Phase II work.

* Information listed above is at the time of submission. *

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