Aluminum Alloy Development and Use in Additive Manufacturing Process Design for Drive System Gear Boxes

Aluminum Alloy Development and Use in Additive Manufacturing Process Design for Drive System Gear Boxes

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N00014-14-P-1137
Agency Tracking Number: N141-062-0417
Amount: $149,989.00
Phase: Phase I
Program: SBIR
Awards Year: 2014
Solicitation Year: 2014
Solicitation Topic Code: N141-062
Solicitation Number: 2014.1
Small Business Information
1820 Ridge Avenue, Evanston, IL, 60201-3621
DUNS: 000000000
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Jason Sebastian
 Manager of Technology and
 (847) 425-8227
 jsebastian@questek.com
Business Contact
 Raymond Genellie
Title: Vice President - Operatio
Phone: (847) 425-8211
Email: rgenellie@questek.com
Research Institution
N/A
Abstract
In this Phase I SBIR program, QuesTek Innovations, a leader in the field of integrated computational materials engineering (ICME), proposes to design and develop novel aluminum alloys specifically optimized for the unique processing conditions and challenges of Additive Manufacturing processing. QuesTek is uniquely suited to rapidly designing new aluminum alloys specifically optimized for AM processing using its advanced Materials by Design stage-gate alloy development process, which is based upon computationally-implemented mechanistic models to predict process-structure and structure-property relationships. Engineers at Bell Helicopter have expressed direct interest in the development of new Al-based alloys for AM, and will act as the voice-of-the-customer to define material property objectives and processing constraints for cast helicopter drive system gear box components. Technical feasibility will be demonstrated in Phase I using pilot-scale powder production (Valimet, Inc.) and leveraging the DMLS production facilities and expertise of manufacturing partner Harvest Technologies (a leader in DMLS-based AM technology). QuesTeks partnership provides a close partnership between material designer (QuesTek), AM manufacturer (Harvest) and OEM user (Bell). Material will be evaluated for microstructure, homogeneity and key mechanical properties (particularly strength, ductility and modulus) to demonstrate the ease of processing of the optimized chemistry and feasibility in achieving target properties.

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

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