AMMO WG Teleconference Minutes – 3 Mar 2021
On 3 March 2021, the Additive Manufacturing Maintenance Operations (AMMO) working group conducted a teleconference with approximately 68 participants. A summary follows:
Introduction: Greg Kilchenstein welcomed the group and provided an overview of the agenda.
Rapid, Large Scale, Additive Manufacturing Prototype (R-LAMP) – Jose J. Doval (3D Systems) described RLAMP as an ARL sponsored effort to develop a next generation system to incorporate new technologies into a large format AM platform. The RLAMP in San Diego is fully integrated with process studies ongoing. He described the technology elements and the part consolidation advantage, then presented a build rate example. A second R-LAMP is being constructed at ARL in Aberdeen Proving Ground, MD. Cosima Boswell-Koller (NCMS) provided information on an R-LAMP live webinar to be conducted on Thursday, March 25th. Registration opens Monday, March 8th. Visit www.ncms.org to learn more.
Cold Spray Technology – Dr. Matt Siopis (OCCDC-ARL) provided an overview of the cold spray process, capabilities, and benefits. He also described a typical spray booth configuration and characteristics, as well as the nozzle equipment and powder materials used. He described bonding characteristics and testing as well as cold spray system comparisons. He followed up with a description of some examples of successful cold spray repairs.
June AM Virtual Workshop – Kelly Visconti (OSD-MANTECH) provided a status of the ongoing planning for the 2021 virtual AM Workshop. There will be a few format changes from last year based on feedback received. This year, the workshop will be conducted in shorter time periods spread out over a 2-3 week period. This will allow participants more time to complete other tasks so they are not pulled away from the workshop. We are looking at about 8 hours per topic area plus a kick-off session and ending with a closing session where topic area out briefs will occur. An example topic area schedule could be meeting on Tuesday from 1-5 for 2 weeks.
We are working on finalizing the dates, topics and co-leads and should have finalized next week. The tentative dates are June 7-21. The topics include some from last year and some new topics. The tentative topics are:
- R&D to Advance Qualification and Certification – addressing user and developer gaps
- AM Network Response
- Workforce Development
- AM Standards
- AM Acceptability
- Continuation of discussion on Metrics
We are also looking to address some topics that may not take 8 hours. Perhaps short 1-2 hour sessions. More information will be coming out in the next couple weeks.
America Makes Mx and Sustainment Advisory Group Update – Marilyn Gaska (LMCO) provided an update that included the following:
- February monthly meeting
- Preparing for virtual 2021 AM Workshop. (See above section) The 2020 AM Workshop report is on the AMMO website at https://ammo.ncms.org/
- Featured speaker was Melanie Lang from FormAlloy, who spoke at the AMMO WG last month on “Metal Deposition for Sustainment & Repair”.
- Had an update on a Rapid Innovation Fund (RIF) call for parts family. It closes on Monday. The announcement to go forward is planned for the 15th.
- March 23-24 is the next virtual Technical Review & Exchange (TRX). You can register at https://www.americamakes.us/events/america-makes-trx-boeing/
- AMSC’s Design for Additive Manufacturing (AM) Virtual Event is March 31. You can register at https://www.americamakes.us/events/amscs-design-for-additive-manufacturing-am-virtual-event/
- Next meeting is 18 March
MxD Update – Frederico Sciammarella (MxD) and Romina Lara presented a Pathfinder Project phase I and Phase II summary.
Phase I involves securing 3D printers in manufacturing. The three objectives are:
- Categorization of information systems
- Selecting, implementation, and self-assessment of security controls
- Compilation of artifacts and submission of security authorization package
Deliverables include a system security plan, risk assessment report, and security technical implementation guide.
Phase II is cybersecurity for AM enterprise operations and has four objectives:
- Markforged and SSP implementation
- SSP Implementation on other FDM printers
- FDM playbook on a second class of FDM printers
- Safeguarding hardware/architecture
Next Meeting: – The next AMMO WG call is scheduled for 10:30-12:00 am (Eastern Time) on Wednesday, 7 April 2021.
POC for this action is Ray Langlais, LMI, firstname.lastname@example.org, (571) 633-8019
(LAMP) – Jose J. Doval (3D Systems) / Cosima Boswell-Koller (NCMS)
Q1. Does the swappable build plate enable the R-Lamp to print multiple parts made of various materials?
A1. It does, but due to contamination concerns, you basically have to clean out the system of previous powder used and load the next powder.
Q2. How long does it take R-LAMP to print a 1mXIM part?
A2. If you were to load up the powder bed, fully loaded up, worst case range would be in the span of 4 weeks.
Q3. Along with the time savings and weight reduction, does R-LAMP provide cost savings over traditional manufacturing?
A3. I believe it does when you consider part consolidation. All the fixes and tooling are eliminated.
Q4. Any issues with overlap between laser coverage fields? Any problems with vapor removal over the large area?
A4. Actually, we stitch the part in several areas. We’ve seen no difference in properties with stitched. We ensure we don’t create a “witness line” or connection point. In reference to fume extraction, we leverage ideas from aviation to ensure no flow separation. We performed a lot of studies and it looks good.
Cold Spray Technology – Matt Siopis (OCCDC-ARL)
Q1. The explosive welding analogy in the one figure requires very high strain rates. What is the strain rate in cold spray?
A1. Powder particles travel at Mach 1-5. The stream rates are very high.
Q2. Can you discuss the biggest challenges to wide adoption of cold spray for qualified structural and non-structural repairs?
A2. Oftentimes it is the local engineering authority that approves the repair. We work with the engineering authority on site.
Q3. How extensible is cold spray repair data from one approved part to another candidate part? Where would an interested DoD party locate the data?
A3. A cold spray recipe should be transferable if all the equipment, powder, and process are the same. The data set collection is what we are trying to do now. Our goal is to make the properties available DoD-wide.
Q4. What fraction of the melting temp do you try to achieve during cold spray?
A4. It depends on the material. i.e. aluminum has a higher percentage of melting point. It could be 2/3 or more. Higher density materials are less.
Q5. How do artisans obtain cold spray training?
A5. There are cold spray OEMs that provide training on site for the organization. We typically see on-site support available until the site is running fully.
Q6. Can you please comment on bond strength/base metal strength ratio?
A6. I would need the specific bond. Higher strength (steel) is about 30-55 KSI, where Aluminum is 15-20-25 KSI.
Q7. If we were to prioritize cold spray repair approval at the enterprise level, where should we start based on current knowledge and short term ROI?
A7. We are sort of doing it now by looking at more common materials and developing a dataset.
Q8. Can you discuss how CSAT is promoting collaboration for cold spray repairs across DoD?
A8. The 2021 Cold Spray Action Team (CSAT) annual meeting is June 22-23. The CSAT is essentially a working group created to allow team members to make connections and collaborate. Any company can showcase their results and exchange information. We have a wide variety of domestic and international companies.
June AM Workshop – Kelly Visconti (OSD-Mantech)
America Makes Mx and Sustainment Advisory Group – Marilyn Gaska (LM)
MxD Update – Frederico Sciammarella (MxD)
Q1. Is this something that MxD will go out with a solicitation?
A1. Generally we send out solicitations for this. I think we did for this one.