Electron Beam Freeform Fabrication: A Fabrication

Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability Robert A. Hafley Karen M. Taminger NASA Langley Research Center

Robert.A.Hafley@nasa.gov

International Conference on Additive Manufacturing 7-8 July 2010

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Outline

Technology inception Characterization Technical challenges Current applications Influence on future designs Supportability in space

Robert.A.Hafley@nasa.gov

Outline

Technology inception

Motivation EBF3 process description Benefits

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Characterization Technical challenges Current applications Influence on future designs Supportability in space
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Metal Deposition Processes

Laser
5-10% 5-10% Continuous gated pulsed Mirrors or Mirrors or fiber optics fiber optics Inert gas Powder, Powder, 5-85% 5-85% 0.5-9 lb/hr
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E-Beam
Energy Energy efficiency efficiency Beam control Beam delivery Beam delivery Environment Feedstock Feedstock efficiency efficiency Max dep. rate 95% 95% Continuous, rastered Magnetically Magnetically steered steered Vacuum Wire, ~100% Wire, ~100% > 30 lb/hr
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EBF3 Core Technology

Rapid metal fabrication process

Layer-additive process No molds or tools Properties equivalent to wrought Demonstrated on Al, Ti, Ni, Fe-based alloys

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EBF3 Process

Slice CAD drawing E-beam creates melt pool Add wire to pool Translate layer-by-layer

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LaRC EBF3 System #1

42 kW gun 60 kV max 6-axis positioning

2m x 2.8m x 2.5m vacuum chamber 600mm x 1200mm x 1500mm build envelope

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EBF3 Demonstration

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Benefits of EBF3

Near-net shape

Minimize scrap Reduces part count Lightweight Enhanced performance Integral structures Functionally graded materials

Efficient designs

Complex unitized components

Green manufacturing

Minimal waste products Energy and feedstock efficient

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EBF3 Saves Resources

Conventional Machining:

3000 kg 2850 kg

=
150 kg

Additive Manufacturing via EBF3:

+
100 kg
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+ EBF3
100 kg

50 kg

=
150 kg
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Outline

Technology inception

Characterization

Microstructure Mechanical properties

Technical challenges Current applications Influence on future designs Supportability in space

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2219 Al Microstructure
Machined from plate Built by EBF3

0.25 mm

0.25 mm

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2219 Al EBF3 Microstructure

As-deposited T6 Condition

100 m 100 m

Rapid cool cast:

Cu

Transformed:
Grain

segregation Dendrites
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boundaries retained
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2219 Al Tensile Data

Tensile Strength, ksi

75 50 25 0 Yield

EBF3 + T62 T62 typical

Elongation, %
14

10 0

Ultimate

Elongation

EBF3 tensile properties comparable to handbook data

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Ti-6Al-4V Microstructure

50 m

2 mm 2 mm

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Ti-6Al-4V Tensile Data

Tensile Strength, ksi
As-deposited Annealed (Wrought)

100 50 0 Yield Ultimate Elongation

10 5 0

EBF3 Ti-6-4 equivalent to annealed wrought product

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Elongation, %

150

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Outline
2219

Technology inception Characterization

Technical challenges

Preferential vaporization Process control Residual stress

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Current applications Influence on future designs Supportability in space

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Loss of Al in Ti-6Al-4V

Al loss in vacuum Function of temperature and pressure Process repeatability Issue with other alloys too
90.5

5 mm

Ti
89.5

Al

6.6 5.4

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Need for Process Control

Melt pool changes with temperature Monitor for process control

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Thermal Residual Stresses

Localized heat induces distortion and residual stress

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Outline

Technology inception Characterization Technical challenges

Current applications

Replace existing parts Enable new complex parts

Influence on future designs Supportability in space

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Add Details onto Forgings

Add features onto simplified preform Reduces billet sizes and buy-to-fly ratio

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Cryotank Concept

Form cylinder EBF3 stiffeners Tailored stiffener arrays

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Complex Shapes

Build entire part Unitized structures Allows internal cavities

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Outline

Technology inception Characterization Technical challenges Current applications

Influence on future designs

New unitized structural designs Functionally-graded structures Integrated systems

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Supportability in space
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Novel Structural Designs

Curved stiffeners can be optimized for:

Performance Low weight Low noise Damage tolerance

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Aeroelastic Tailoring
Monocoque wing Coupled bendingtorsion wing

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Design for Acoustics

Optimize stiffeners to tailor natural resonance frequencies

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Functional Gradients

Locally control:

Chemistry Microstructure Properties Lengthwise gradient

Build height gradient

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Outline

Technology inception Characterization Technical challenges Current applications Influence on future designs

Supportability in space

In-space repair Spin-off applications

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Need for Supportability

Long duration missions Support autonomy Minimize resupply from Earth Fab or repair parts Enhances mission success
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Remote Terrestrial Repairs

Similar self-supportability needs on Earth:

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Navy ships Army supply in-theater Remote science bases

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Summary

Led by LaRC since inception Disruptive technology Cross-cutting:

Aeronautics Space Other industry sectors

Enables new structural designs Demonstrated in 0-g for use in-space

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