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Computationally Driven Reliability & Repeatability for Wire Arc Additive Manufacturing of High Strength Maraging 250 Steel

Award Information
Agency: Department of Defense
Branch: Army
Contract: W56HZV-23-C-0038
Agency Tracking Number: A2-9518
Amount: $1,150,000.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: A21C-T023
Solicitation Number: 21.C
Solicitation Year: 2021
Award Year: 2023
Award Start Date (Proposal Award Date): 2023-09-12
Award End Date (Contract End Date): 2025-09-11
Small Business Information
104 Prescott St.
Worcester, MA 01605-1111
United States
DUNS: 080880428
HUBZone Owned: Yes
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Aaron Birt
 (717) 602-5158
Business Contact
 Aaron Birt
Phone: (717) 602-5158
Research Institution
 Worcester Polytechnic Institute
 Michelle Mulkern
100 Institute Rd
Worcester, MA 01609-2247
United States

 (508) 831-6158
 Nonprofit College or University

Challenge: Reliable & repeatable production of large format, high performance components that are difficult to source using conventional casting and forging methods. We will Deliver: A physics-based modeling framework that enables reliable and repeatable large-format component-level production of high strength (>200 ksi) Maraging Steel produced via Wire-Arc Additive Manufacturing (WAAM). Proposal: Solvus Global, Mississippi State University, and Worcester Polytechnic Institute will scale the modeling framework deployed in Phase I to account for various geometries and asymmetries present in production of a large format part. This modeling framework will be proven via the fabrication of a full-scale part. Vision/End State: The ability to identify to fabricate any large-format component of Maraging Steel, with minimal process optimization by leveraging the physics-based modeling framework to eliminate unwanted microstructural features and residual stress buildup. This framework will be scalable and deployable to other material systems of interest as part of a Phase 3 effort. Competitive Advantage: The team of Solvus Global, Mississippi State University (MSU), and Worcester Polytechnic Institute (WPI) has already demonstrated material performance of Maraging 250, and has demonstrated the ability to predict build windows from physics-based models. A proprietary framework of data transfer from experimental to thermal model to microstructural model and back provides the team with the ability to accelerate deployment of new material systems faster than any other group in the world.  Furthermore, Solvus Global has all of the necessary infrastructure to immediately enter into production arrangements leveraging the outcomes of this Phase II SBIR. By end of 2022 Solvus Global will have three production-level WAAM cells capable of producing parts up to 20’ and 4000 pounds. Solvus will have the ability to machine parts up to 10’ x 8’, and will have the ability to heat treat parts up to 5’ x 5’.

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

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