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Ceramic Additive Manufacturing for Metal Castings

Award Information
Agency: Department of Defense
Branch: Defense Logistics Agency
Contract: SP4701-17-C-0027
Agency Tracking Number: L2-0081
Amount: $999,971.00
Phase: Phase II
Program: SBIR
Solicitation Topic Code: DLA152-003
Solicitation Number: 2015.2
Solicitation Year: 2015
Award Year: 2017
Award Start Date (Proposal Award Date): 2017-04-20
Award End Date (Contract End Date): 2019-04-19
Small Business Information
133 Defense Highway, Suite 212
Annapolis, MD 21401
United States
DUNS: 153908801
HUBZone Owned: No
Woman Owned: Yes
Socially and Economically Disadvantaged: No
Principal Investigator
 Walter Zimbeck
 Manager, 3D Printing
 (410) 987-8988
Business Contact
 Sharon Fehrenbacher
Phone: (410) 224-3710
Research Institution

Additive manufacturing of integrally cored ceramic molds promises substantial cost savings and much shorter development cycles for the cooled blades and vanes of the high pressure turbine section of aircraft engines. AM directly prints the ceramic mold and core as a monolithic body, thereby eliminating the major steps of ceramic core and wax pattern fabrication. Based on a cost analysis conducted during the Phase I project, the cost savings include: lower cost per casting by replacing core and wax pattern fabrication with cored mold fabrication, large reduction in upfront tooling related costs, savings on core tooling replacement costs, and the potential to realize cast-in film cooling holes and avoid the cost of drilling. This Phase II project is structured with multiple casting trials demonstrating different airfoil designs. Candidate designs range from small with simple radial flow cooling schemes to larger and more complex serpentine schemes, to large multi-wall airfoils. Material and process development efforts are planned before each casting trial and root cause corrective action assessments will be conducted after each casting trial. The project culminates by re-evaluating the cost model developed in Phase I and assessing the benefits with the improved process.

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

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