Electron-Beam Additive Manufacturing Process Control for Titanium Alloys

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-09-M-5230
Agency Tracking Number: F091-002-0004
Amount: $99,832.00
Phase: Phase I
Program: SBIR
Awards Year: 2009
Solicitation Year: 2009
Solicitation Topic Code: AF091C-002
Solicitation Number: 2009.1
Small Business Information
Keystone Synergistic Enterprises, Inc.
698 SW Port Saint Lucie Blvd, Suite 105, Port Saint Lucie, FL, 34953
DUNS: 114133213
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Bryant Walker
 Program Manager
 (772) 343-7544
 Bryant@KeystoneHQ.com
Business Contact
 Bryant Walker
Title: President
Phone: (772) 343-7544
Email: Bryant@KeystoneHQ.com
Research Institution
N/A
Abstract
Titanium forgings are high cost and long lead time items which negatively impact aircraft manufacturing costs and cycle times.   Additive manufacturing of titanium structural parts has the potential to reduce lead and cycle times, work in process, and the amount of titanium required to produce structural parts.  Additionally, additive manufacturing can be used to fabricate or repair components/spares in small production runs and to produce prototypes where tooling or conventional manufacturing costs would be prohibitive.  The focus of this effort will be to develop and demonstrate wire-feed electron beam additive manufacturing (eBAM) techniques and control processes to produce flight worthy titanium alloy structural aerospace components typically used in DoD aerospace production programs.  Special emphasis will be given to the demonstration of the sensors and systems necessary for closed-loop control of the deposition parameters, critical to the quality of the component.  Additionally,  establishment of a detailed business case will be completed to show that the optimized eBAM solutions are competitive with existing titanium forging processes in terms of cost, quality, lead and cycle times, WIP, etc. BENEFITS: This proposed project will benefit military aircraft and engine systmes by developing and validating a high quality and cost effective method for electron beam additive manufacturing of titanium structural components.

* information listed above is at the time of submission.

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