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On 5 May 2021, the Additive Manufacturing Maintenance Operations (AMMO) working group conducted a teleconference with approximately 50 participants. A summary follows:
Introduction: Greg Kilchenstein (OSD-MR) welcomed the group and provided an overview of the agenda.
Update on Recent AM Activities at ARL PSU – Ted Reutzel (PSU) described several additive capabilities being developed and tested to include Large Format Powder Bed Fusion AM, wire arc AM, and digital x-ray inspection. He then discussed repair with Laser Based Directed Energy Deposition which offers better control enabling reduced heat input. He also detailed quality assurance in laser‐based directed energy deposition (DED) & powder bed fusion (PBF) additive manufacturing, using multiple images and graphs to highlight the process and results. He followed that up with a brief description of machine learning to automated process monitoring and in‐situ defect detection for AM through multi‐modal sensor fusion, and a quick highlight of demonstrating equivalency for AM.
Hexcel AM Materials Manufacturing – Bob Yancy (Hexcel) provided a review of several projects they are working on to include HexPEKK-100 high performance thermoplastic AM, which is a blend of 85% polyetherketoneketone (PEKK) and 15% carbon fiber. He described the HexAM aerospace production facility which is using the HexPEKK-100 to print flight-ready hardware. The printed parts can be used to replace metallic castings and are proven, cost-effective, and qualified on commercial and defense air and space vehicle platforms. They are America Makes qualified, NIAR industry qualified, and in the F-35 Navy ManTech production qualification program.
America Makes Mx and Sustainment Advisory Group Update – Marilyn Gaska (LMCO) provided an update that included the following:
- 15 April monthly meeting
- Preparing for virtual 2021 AM Workshop. (Kelly to Provide Update)
- Deep dive was a presentation on Cold Spray from Aaron Nardi.
- In April there was a virtual Technical Review & Exchange (TRX). Presentations are available in the Digital Library for members.
- Upcoming events include The Aircraft Airworthiness & Sustainment Conference on 16-19 August.
- Next week’s AMMSAG meeting includes a briefing on Rapid Large-Scale Additive Manufacturing Prototype (RLAMP).
- May events include:
- May 6 – Manufacturing Innovation Institutes Integral to U.S. Pandemic Response
- May 12-13 – Digital Twin Summit
- May 14 – 5th Additive Manufacturing Center of Excellence Snapshot Workshop
- May 18 – AIM Higher DOD Supply Chain Event (Virtual)
- May 19-21 – NSF’s Industry-Academia Collaboration in Advanced Manufacturing Virtual Workshop
- To register for events go to americamakes.us
June AM Virtual Workshop and JAMWG Update – Kelly Visconti (OSD-RE) provided a status of the ongoing planning for the 2021 virtual AM Workshop to be conducted 14-21 June.
- Registration closes May 21st
- Working groups will consist of seven work groups in key disciplines
- Working groups meet 4 hours on Tuesday & Thursday
- There will be a “University Day” with optional sessions on Wednesday where you will have the opportunity to learn from experts on select topics.
The seven working groups are:
- R&D to Advance Qualification and Certification
- Education and Workforce Development
- AM Standards
- Integrated AM Network Response
- AM Decision Making – Business Case Analysis
- AM Acceptability – Common AM Data Package Approach (JAMA) – Tuesday Only
University Topics are:
- One Size Doesn’t Fit All: The Role for Technology in Meeting the Multiple Workforce Challenges in Manufacturing
- Training: JAMMEX Introduction (Gov’t Only)
- DoD Additive Manufacturing Draft Guidebook Review
- Cybersecurity in Manufacturing Workforce
A brief outline of the agenda:
- June 14 (Day1) Opening Remarks, Overview, & Work Group Intro Briefs
- June 15 (Day 2) Working Group Sessions
- June 16 (Day 3) “University Day” (Optional Sessions)
- June 17 (Day 4) Working Group Sessions
- June 21 (Day 5) Overview, Working Group Out Briefs, Closing Remarks
To register, go to: https://ammo.ncms.org/events/2021-additive-manufacturing-workshop/
- May 17-18 – AM Workshop Civil Engineer Group – Let Kelly know if you intend to join. They will be working on a document defining Digital Twin and are looking for comments. Must have a .mil address.
- Work continues on developing AM Decision Tools
- A public advisory group is working on a publicly allowable database for the metal side.
Next Meeting: – The next AMMO WG call is scheduled for 10:30-12:00 am (Eastern Time) on Wednesday, 2 June 2021.
POC for this action is Ray Langlais, LMI, firstname.lastname@example.org, (571) 633-8019
Update on Recent AM Activities at ARL PSU – Ted Reutzel (PSU)
Q1. How fast is the new 3D systems capability? How long does it take to manufacture a larger component?
A1. I don’t have those numbers. A lot of our processes are done with 500w. It is at least 3x faster than standard powder systems.
Q2. Is the Qualification Test Plan for acceptance of AM repairs less onerous than for new parts?
A2. It might be. All are a little bit different. At NAVAIR there is a well-defined path for acceptance. We are in the process of qualifying, and haven’t completed yet.
Q3. Are the integrated sensors being incorporated into production AM Machines yet?
A3. We have some examples that are available on commercial systems. We encourage it if it makes sense. It is certainly not currently on a broad scope.
Q4. Can you discuss wire-based repair qualification vs. powder-based repair qualification?
A4. That’s a deep topic. Wire-based has significant obstacles. For example, there are only a few approved wires. They are also easy to melt if the heat is too high.
Q5. What are the applications for rapid repair robot (slide 53)?
A5. There are a lot of applications in the ship building and repair industry. Grinding, stripping, and inspection tasks such as corrosion and paint removal, as well as some structural repair. I’m sure there are other applications in aircraft and ground vehicles that I’m not familiar with.
Hexcel AM Materials Manufacturing – Bob Yancy
Q1. Has COVID affected Hexcell’s ability to meet DoD customers’ demands for your products?
A1. It has had a major impact on Hexell as 2/3rd of our business is from commercial aviation. However, the defense side has been stable. We had some staffing issues early on, but we are beyond that now and operating as we did pre-COVID.
Q2. What type of parts are most applicable for this new process?
A2. The biggest value is castings – new or replacement. On the commercial side, we do a lot of covers for different systems, and some work on bonding.
Q3. What is the cost advantage over metal casting?
A3. The cost advantage is greatest for low volume manufacturing. The cost of tooling is amortized over the volume, so removing the tooling costs impacts low volumes the most.
America Makes Mx and Sustainment Advisory Group Update – Marilyn Gaska (LMCO)
AM Workshop & JAMWG Updates – Kelly Visconti (OSD-RE)
Date(s) - 05/05/2021
10:30 AM - 12:00 PM