On 1 August 2018, the Additive Manufacturing Maintenance Operations (AMMO) working group conducted a teleconference with over 60 participants. A summary follows:
America Makes & ANSI Additive Manufacturing Standardization Collaborative (AMSC) Roadmap Update – American National Standards Institute (ANSI): Jim McCabe briefed the group on America Makes and the ANSI publication, “the Standardization Roadmap for Additive Manufacturing (version 2.0)” published in June 2018. The roadmap is the work product of the America Makes & ANSI Additive Manufacturing Standardization Collaborative (AMSC), a group chartered to coordinate and accelerate the development of industry-wide additive manufacturing standards and specifications. More than 300 subject matter experts supported the roadmap’s development with substantial representation from the aerospace, defense, and medical industries.
The new roadmap describes the current AM standardization landscape and identifies 93 “gaps” where no published standard or specification currently exists to address a particular industry need. In 65 of those gaps, additional pre-standardization research and development (R&D) needs are identified. Updates are provided on progress against gaps identified in the earlier version of the roadmap, with many gaps having been substantially revised. A number of new gaps also have been described, many involving polymers. The document considers the life cycle of an AM part, from initial design, to materials and process selection, production, post-processing, finished material properties, testing, qualification, and maintenance. Envisioned future work includes ongoing roadmap promotion, tracking progress to address the gaps, and potentially sector-specific workshops. The Maintenance and Repair section of the roadmap has been revised to better differentiate between maintenance of AM machines and additive repair processes. A new gap on laser based additive repair has been added. A section on finishing and assembly has been renamed surface preparation for additive repair. A gap on using AM to print tools was withdrawn.
SPEE3D: Steven Camilleri, CTO of SPEE3D, briefed the group on how SPEE3D has developed a new form of metal 3D printing technology that allows parts to be produced 1000 times faster and 100 times cheaper than conventional SLM style 3D printing. This new technology suits both manufacturing (the replacement of metal casting) and parts on demand, for application such as repair and maintenance. The LightSPEE3D printer was launched in November and is commercially available now. The technology works without melting the metal, using the kinetic energy from supersonic deposition velocities. This allows high quality, high-density metal parts to be manufactured directly from a CAD model or 3D scan. Two materials are at a mature stage of development. Aluminum 6061 for mechanical parts, which exceeds the requirements of the UNS03560 cast material. Pure copper for electrical or thermal parts, which is able to exceed 93% of IACS (the Internationally Accredited Copper Standard).
Additive Manufacturing, Materials, and Processes (AMMP) – NCMS: Jon Riley briefed the group on an OTA and Cooperative Agreement that NCMS has recently signed with Army ARL. AMMP is a consortium of industry (big and small), academia, and government focused on creating next generation manufacturing breakthroughs to meet warfighter needs in 5, 10, and 20 years. The focus is on enabling the U.S. industrial base with unprecedented speed in part production; novel designs and materials (unattainable with current technology); dramatic cuts in cost and delivery times; and point‐of‐need part manufacturing (reduced logistical tail / in‐theater warehousing). AMMP is divided into three markets: research and invention, which his mainly public and innovation ready; the commercial market, which is private sector and investor ready; and the innovation market, which is a public and private collaboration. There is a five step proven model and process: formation, approval, execution, closeout, and transition with a team of end users, investors, integrators, developers, talent, and the infrastructure to support it.
Riley highlighted the six technology focus areas for AMMP, which follows: (1) Essential Science and Technology for Advanced Manufacturing, Materials, and Processes (EST-AMMP); (2) Feedstocks for Additive Manufacturing (FAM); (3) Innovative Design Integrating Additive Manufacturing Processes (iDIAMP); (4) Process Visualization, Sensing, Probing, and Feedback toward Real-Time Additive Process Control (RTAPC); (5) Materials Manufacturing Science and Technology for Lethality (M2S&T-L); and (6) Materials Manufacturing Science and Technology for Protection (M2S&T-P)
MELDTM– MELD Manufacturing: Nanci Hardwick briefed the group on MELD Manufacturing Corporation’s proprietary MELD technology, which is a solid-state, thermo-mechanical AM process that yields fully-dense products with near wrought properties, reduced distortion, high deposition rates, and significantly faster throughput as post deposition material-processing (HIP, sintering, etc.) is not required. During the MELD process, a filler material is forced to flow between the rotating MELD tool and the substrate, whereby the filler material undergoes severe plastic deformation, dynamic recrystallization, and deposition. MELD can be used for the deposition of metal, metal matrix composites (MMCs), thermoplastics, etc. Due to its additive nature, MELD can be used for coating, repair, joining, or AM applications of both similar and dissimilar materials. MELD is differentiated from other AM technologies because it is a highly scalable, open-atmosphere process with a high deposition rate that offers flexibility with material sets and yields a near wrought microstructure on near-net-shape complex 3D structures.
MELD machines are large-scale, open-atmosphere systems that do not require a laboratory environment for reliable operation. These machines are robust and durable and are well suited for deployment in either a depot or forward operating base environment, among others. MELD machines use substantially less energy than traditional melt-based systems; having power requirements comparable to a CNC machine. The ability for our Nation’s war fighters to maintain and repair the Next Generation Combat Vehicle by performing repairs on the vehicle or printing new components on-demand in the field would not only improve operational efficiency but also reduce the overall cost and overhead associated with holding replacement parts in inventory. Enabling the ability to additively manufacture and repair components as close to the battlefield as possible will offer a tremendous strategic advantage with regards to agility, improvements to asset utilization, and a reduction in the risks associated with supply chain operations.
MELDTM is a low-cost, environmentally friendly, and solid-state AM and repair technology that does not require the utilization of delicate laboratory-grade equipment, such as vacuum chambers, laser and e-beam systems, or powder beds. Traditional AM and related repair technologies require that the deposited or repaired materials be melted during application. Because of the melting of the metal material, substantial differences may exist within the deposited materials, leading to inconsistent mechanical properties along specific part sites and/or directions. In such cases, parts fabricated via these traditional melt-based technologies can exhibit inferior properties in comparison to conventionally manufactured components. The problems found within these components often stem from the melting and re-solidification and can include a brittle cast structure, hot cracking, and porosity, all of which can lead to a reduction in the overall mechanical performance. MELD technology was developed to overcome the above-mentioned shortcomings of these more traditional melt-based metal AM and repair processes. Patent protected, and award-winning MELD systems and associated MELD technologies are truly disruptive innovations.
America Makes AM Mx and Sustainment Advisory Group Update – Lockheed Martin – Marilyn Gaska provided the following update:
- Rich Lonardo, YBI, represented AFS for American Foundry Society for Metal Castings Conference Preview, Brandon Lamoncha, Humtown Products (10-13 Sept 2018, Louisville, KY)
- AM M&S Parts Classification for AM Working Group Update – Susan Moehring/Marilyn Gaska
- Susan has summarized inputs to date. Focused discussion on deliverables
- At July 27 meeting Dr. David Sundquist from Boeing shared definitions from MAMLS Phase II review on July 24th. Welcome additional participants for next discussion on August 11th. Dave Siddle has also joined effort.
- America Makes News – MMX on October 30-31 in Youngstown and project calls.
- The first Directed Project Opportunity focuses on the acceleration of large scale additive manufacturing (ALSAM) with the objective of overcoming known and distinct shortcomings of Selective Laser Melting (SLM) additive manufacturing (AM) that are limiting the wider adoption of the technology for production.
- The second Directed Project Opportunity focuses on advancing AM post-processing techniques (AAPT) with the objective of gaining a better understanding of the available techniques in order to achieve qualified parts and certified processes, and reduce costs.
- AM for M&S Adv Group Face to Face Agenda during MMX Discussion – Inputs requested, following up on AM Business Model Workshop inclusion on agenda
- Next Monthly Telecon is August 17, 2018 at 11AM EST.
Additive Manufacturing for Sustainment Update – OSD (MR): Greg Kilchenstein briefed the group on OSD(MR)’s AM sustainment update:
- The AM DTM Policy informal coordination is complete, with integrated recommendations and comments from the Services and submitting organizations. The official SD106 coordination process has begun for the “DTM 18-XXX, Interim Policy and Guidance for the Use of Additive Manufacturing in Support of Materiel Sustainment” via the DoD Issuances and Directives Portal. The DTM will be in effect, hopefully, by COB this calendar year. This will be the first DoD-wide AM sustainment focused policy.
- AM Contracting Guide has secured additional resources through the Navy and USMC to continue the effort and progress of the working group with the ultimate result of the guide being a mutual benefit for DoD, Industry, and Academia.
- 2018 DoD Maintenance Symposium is 17-20 December in Tampa, FL at the Tampa Convention Center (Register here: https://www.sae.org/events/dod/)
- AM Breakout is on 17 Dec from 0800-100 in Ballroom A. This breakout will provide an open discussion that highlights AM and additive repair opportunities within the DoD maintenance community, and the successes, challenges, and way forward to realizing the AM potential across DoD maintenance and supply.
Next Meeting: – The next AMMO WG call is scheduled for 10:30-12:00 am (Eastern Time) on Wednesday, 5 September 2018.
POC for this action is Ashley Mitchell, LMI, email@example.com, (571) 209-2629
Date(s) - 08/01/2018
10:30 AM - 12:00 PM