Rapid Part Qualification Methodology of Aircraft Metallic Components using Direct Digital Manufacturing Technologies

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N00014-12-C-0411
Agency Tracking Number: N111-077-0219
Amount: $490,133.00
Phase: Phase II
Program: SBIR
Awards Year: 2012
Solicitation Year: 2011
Solicitation Topic Code: N111-077
Solicitation Number: 2011.1
Small Business Information
664 NW Enterprise Drive, Suite 118, Port Saint Lucie, FL, -
DUNS: 114133213
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Bryant Walker
 President
 (772) 343-7544
 bryanthwalk@aol.com
Business Contact
 Bryant Walker
Title: President
Phone: (772) 343-7544
Email: bryanthwalk@aol.com
Research Institution
 Stub
Abstract
Metal Digital Direct Manufacturing (MDDM) or layer-by-layer additive manufacturing is inherently green, produces near net shapes, reduces labor content, and does not require the use of special tooling to fabricate components. However, the process struggles to gain wide acceptance for producing aerospace and defense metal components due to two key issues. First, current powder and wire feed processes struggle to maintain high uniformity of part dimension and microstructure. Second, the current time required to qualify a MDDM component is so excessive it greatly restricts overall acceptance and usage of the process. In response, Keystone is developing, for implementation during this project, an adaptive feed-forward process control with feedback monitoring to ensure the process accounts for the thermal latency and thereby sustain aerospace levels of quality throughout the deposited component. Thus, this proposed project will utilize a wire feed, laser based MDDM system to build and validate a hybrid feed-forward / feedback monitoring capability, validation of a Rapid Process Qualification methodology and complete MDDM of a selected component.

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

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