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Additive Manufacturing: From Rapid Prototyping to Flight
Tracie Prater, Ph.D.Aerospace Engineer, Materials and Processes Laboratory
NASA Marshall Space Flight CenterHuntsville, AL
https://ntrs.nasa.gov/search.jsp?R=20150006951 2018-05-17T18:36:47+00:00Z
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About Me
B.S. Physics from Eastern Kentucky UniversityM.S., Ph.D. Mechanical Engineering from Vanderbilt
Previously worked as a materials engineer at United Launch Alliance (ULA)
currently an aerospace engineer in the Materials and Processes Laboratory at NASA Marshall Spaceflight Center
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Then…..
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Now
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NASA Field Centers
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NASA’s Four Core Mission Areas
Science Space Technology
Human Exploration and Operations Aeronautics
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Current Human Spaceflight Architecture
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Space Launch System (SLS) Initial lift capacity of 70 MT, evolvable to 130
MT Carries the Orion Multipurpose Crew Vehicle
(MPCV) First flight of SLS in 2018
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What is Additive Manufacturing?
‐ASTM F42 defines AM as “the process of joining materials to make objects from 3D model data, usually layer by layer, as opposed to subtractive manufacturing methodologies”
‐AM machine software slices a CAD model file into layers
‐base material can be metallic, plastic, ceramic, composite, or biological
‐2.2 billion dollar industry and U.S. is the world leader in industrial AM systems
‐AM encompasses a broad range of processes
‐distinguished by techniques used to deposit layers and the way in which the deposited layers are bonded together
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What is Additive Manufacturing?
PhotopolymerizationMaterial Jetting
Binder Jetting
Material Extrusion
Powder Bed FusionSheet Lamination
Directed Energy Deposition
StereolithographyMulti‐jet Modeling (MJM)
Fused Deposition Modeling (FDM)
Selective Laser Melting (SLM)
Electron Beam Melting (EBM)
Selective Laser Sintering (SLS)
Laminated Object Modeling (LOM)
Laser Engineered Net Shaping (LENS)
Additive Manufacturing
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Why Additive Manufacturing?‐Aerospace components have complex geometries and are made from advanced materials
‐Components are difficult, costly, and time‐consuming to manufacture using conventional processes
‐Aerospace hardware represents small batch, low‐rate production
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Why Additive Manufacturing?
Affordability Performance
‐reduced part count
‐fewer critical welds and brazes
‐reduced tooling
‐schedule and cost savings
‐optimized internal flow passages
‐minimized leak paths
‐lower mass
Design for Manufacturing Manufacturing for Design
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History of Additive Manufacturing at NASA MSFC
‐NASA MSFC has 20+ years of experience with AM technologies
‐initial focus in early 1990s on rapid prototyping
‐National Center for Manufacturing Sciences (NCMS)
‐first metallic system: laser engineered net shape parts
‐currently focused on Electron Beam Melting (EBM) and Powder Bed Fusion (PBF) technology for production of propulsion hardware
‐also focused on using AM to build parts in‐space
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Additive Manufacturing at MSFC
For space
In space
Short term Long term
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3D Printing in Space
Caps
Threads
Buckles
Clamps
Springs
Potential Mission Accessories
Containers
The 3D Print project will deliver the first 3D printer on the ISS and will investigate the effects of consistent microgravity on melt deposition
additive manufacturing by printing parts in space.
The 3D Print project will deliver the first 3D printer on the ISS and will investigate the effects of consistent microgravity on melt deposition
additive manufacturing by printing parts in space.
Melt deposition modeling: 1) nozzle ejecting molten
plastic, 2) deposited material
(modeled part), 3) controlled movable table
3D Print SpecificationsDimensions 33 cm x 30 cm x 36 cmPrint Volume 6 cm x 12 cm x 6 cmMass 20 kg (w/out packing material or
spares)Est. Accuracy 95 %Resolution .35 mmMaximum Power 176W (draw from MSG)Software MIS SliceRTraverse Linear Guide RailFeedstock ABS Plastic
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A Vision of In‐Space Manufacturing
‐In‐space fabrication and repair of plastics using 3D printing‐Qualification/inspection of on‐orbit parts using structured light scanning‐Printable small satellite technologies‐On‐orbit plastic feedstock recycling‐In‐space metals manufacturing process demonstration‐Welding in space‐Additive construction using regolith
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Additive Manufacturing at MSFC
For space
In space
Short term Long term
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Additive Manufacturing at MSFC
‐Primary focus on for‐space AM is powder bed fusion processes
‐Electron beam melting (EBM) machine for Titanium
‐Concept Laser M1 and M2 for Selective Laser Melting (SLM) of Inconel 718 and Inconel 625 in addition to Copper alloys
‐addition of Xline expands build volume by a factor of 6
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Selective Laser Melting (SLM) Process Flow
1. 3D CAD model of part sliced into layers2. Laser scan path is calculated which
defines the boundary contour and the fill sequence
3. Powder is fed uniformly onto build plate by a wiper
4. Laser melts the deposited powder layer
5. Melted particles fuse and solidify to form a layer of the component
6. Build table is lowered and additional powder is fed onto plate
7. After part is complete, it undergoes stress relief and EDM is used to separate it from the build plate
8. Part may be subject to additional post‐processing (Hot Isostatic Press and/or heat treatment)
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Selective Laser Melting (SLM)
SLM process development for AM propulsion hardware is a manufacturing optimization problem. Build parameters must be optimized to ensure production of a material that will be able to perform in its intended use environment.
Controlled Process Variables
Base materialPowder characteristicsDeposition patternLayer thicknessHatch spacingLaser powerLaser scan speedPost‐build material conditioning
Material properties
Yield strengthUltimate strengthElongationReduction in areaPlastic strainModulusDensityFracture toughness
Material consolidationHardness Surface roughnessEnvironmental effects Fluid compatibility
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Recent AM Builds at MSFC
‐F1 engine reconstruction
‐In718 1200 lb thrust injector
‐two In718 main combustion chambers
‐In625 nozzle for Morpheus project
‐100 lb injector and fin set for NanoLaunch
‐multiple turbomachinery parts
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NASA MSFC’s role in the broader aerospace additive manufacturing community is three‐fold:
1) Smart buyer
2) Tech transfer
3) Anomaly resolution
Additive Manufacturing at NASA MSFC
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Challenges in Additive Manufacturing
Materials Characterization Standard Design Practices
Process Modeling, Monitoring, and Control
Flight Certification
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Materials Informatics for Additive Manufacturing at MSFC
Development of an AM database will provide a single source data repository that can be used to:
• Characterize materials• Explore relationships between process variables and material
properties• Disseminate validated materials property data to the modeling,
simulation, and design community• Aid in the development of materials standards and protocols
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Additive Manufacturing: The Path to Flight
Certification: the affirmation by the program, project, or other reviewing authority that the verification and validation process is complete and has adequately assured the design and as-built hardware meet the established requirements to safely and reliably complete the intended mission.
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Additive Manufacturing: The Path to Flight
‐Develop part classification approach based on consequences of failure
‐Understand process failure modes
‐Characterize process variability
‐Verify individual build lot quality (lot acceptance testing)
‐Develop guidelines and specifications for AM materials, processes, and design
‐Provide recommendations to vendors on allowable practices and certification limits
‐Incorporate AM materials and processes into existing NASAstandards
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Summary
• Additive manufacturing (AM) offers tremendous promise for the rocket propulsion community.
• Foundational work must be performed to ensure the safe performance of AM parts.
• Government, industry, and academia must collaborate in the characterization, design, modeling, and process control to accelerate the certification of AM parts for human‐rated flight.
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Questions
Tracie Prater, Ph.D.Aerospace Engineer, Materials and Processes LaboratoryNASA Marshall Space Flight [email protected]