Development of a qualification procedure, and quality assurance and quality control concepts and procedures for repairing and reproducing parts with additive manufacturing in MRO processes

This MSc by Research is focused mainly on Quality Assurance (QA) and Qualification Procedures for metal parts manufactured using new Additive Manufacturing (AM) techniques in the aerospace industry. The main aim is to understand the state of the art of these technologies and the strong regulatory framework of this industry in order to develop correct QA/QC procedures in accordance with the certification process for the technology and spare parts. These include all the testing and validation necessary to implement them in the field, as well as to maintain their capability throughout their lifecycle, specific procedures to manufacture or repair parts, workflows and records amongst others. At the end of this MSc by Research, an entire Qualification Procedure for Electron Beam Melting (EBM) and Selective Laser Melting (SLM) for reproduction of an aerospace part will be developed and defined. Also, General Procedures, Operational Instructions, and Control Procedures with its respective registers, activities, and performance indicators for both technologies will be developed. These will be part of the future Quality Assurance and Quality Management systems of those aerospace companies that implement EBM or SLM in their supply chain

Study of the Environmental Implications of Using Metal Powder in Additive Manufacturing and Its Handling

Additive Manufacturing, AM, is considered to be environmentally friendly when compared to conventional manufacturing processes. Most researchers focus on resource consumption when performing the corresponding Life Cycle Analysis, LCA, of AM. To that end, the sustainability of AM is compared to processes like milling. Nevertheless, factors such as resource use, pollution, and the effects of AM on human health and society should be also taken into account before determining its environmental impact. In addition, in powder-based AM, handling the powder becomes an issue to be addressed, considering both the operator´s health and the subsequent management of the powder used. In view of these requirements, the fundamentals of the different powder-based AM processes were studied and special attention paid to the health risks derived from the high concentrations of certain chemical compounds existing in the typically employed materials. A review of previous work related to the environmental impact of AM is presented, highlighting the gaps found and the areas where deeper research is required. Finally, the implications of the reuse of metallic powder and the procedures to be followed for the disposal of waste are studied.This research was funded by the European Union through the H2020-FoF13-2016 PARADDISE project under Grant 723440 and the Basque Government through the ADDISEND project under Grant Elkartek-KK00011

VIABILITY OF ADDITIVE MANUFACTURING FOR PRODUCTION AND TOOLING APPLICATIONS: A DEVELOPMENT OF THE BUSINESS CASE

As marketplace competition drives industrial innovation to increase product value and decrease production costs, emerging technologies foster a new era through Industry 4.0. One aspect of the movement, additive manufacturing, or 3D [three-dimensional] printing, contains potential to revolutionize traditional manufacturing techniques and approach to design. However, uncertainties within the processes and high investment costs deter corporations from implementing and developing the technology. While several industries are benefitting from additive manufacturing’s current state, as the technology continues to progress, more companies will need to evaluate it for industrial viability and adoption. As such, there exists a need for a framework to evaluate the business case for investment review. While many papers in the literature provide cost estimation models for additively manufactured parts, there does not exist a thorough guide for decision making. This master’s thesis report introduces a process to evaluate machine investment and part production between additive manufacturing and traditional manufacturing technologies using operational and financial key performance indicators. A case study application of the process yielded suspect part unit costs 3.71% higher than its literature basis, indicating a viable methodology. The present value total investment cost for an EOSINT M 270 machine tool, with a five-year lifespan, was determined to be $3,241,710 in the case context; breakeven point occurs beyond investment life at 2.28 years. Results were dependent on product valuation and assumptions made. Key output metrics indicated the suspect machine could generate 5,238 units annually at a 1.4 part per hour throughput rate. As part production was deemed feasible under the provided constraints, sensitivity analysis indicated material and equipment costs as cost drivers. Similarly, production drivers were found to be scan rate and machine utilization. Results were consistent with common belief that additive manufacturing is currently viable for small-to-mid series production, or parts of high complexity value. These findings indicate areas of improvement for the additive manufacturing industry for commercialization purposes, and demonstrate a useful methodology for assessing the business case of additive manufacturing

SIMULATING CONSUMABLE ORDER FULFILLMENT VIA ADDITIVE MANUFACTURING TECHNOLOGIES

Operational availability of naval aircraft through material readiness is critical to ensuring combat power. Supportability of aircraft is a crucial aspect of readiness, influenced by several factors including access to 9B Cognizance Code (COG) aviation consumable repair parts at various supply echelons. Rapidly evolving additive manufacturing (AM) technologies are transforming supply chain dynamics and the traditional aircraft supportability construct. As of June 2022, there are 595 AM assets within the Navy’s inventory—all for research and development purposes. This report simulates 9B COG aviation consumable fulfillment strategies within the U.S. Indo-Pacific sustainment network for a three-year span, inclusive of traditional supply support avenues and a developed set of user-variable capability inputs. Simulated probabilistic demand configurations are modeled from historical trends that exploit a heuristic methodology to assign a “printability” score to each 9B COG requirement, accounting for uncertainty, machine failure rates, and other continuous characteristics of the simulated orders. The results measure simulated lead time across diverse planning horizons in both current and varied operationalized AM sustainment network configurations. This research indicates a measurable lead time reduction of approximately 10% across all 9B order lead times when AM is employed as an order fulfillment source for only 0.5% of orders.NPS Naval Research ProgramThis project was funded in part by the NPS Naval Research Program.Lieutenant Commander, United States NavyApproved for public release. Distribution is unlimited

Marshall Space Flight Center Research and Technology Report 2019

Today, our calling to explore is greater than ever before, and here at Marshall Space Flight Centerwe make human deep space exploration possible. A key goal for Artemis is demonstrating and perfecting capabilities on the Moon for technologies needed for humans to get to Mars. This years report features 10 of the Agencys 16 Technology Areas, and I am proud of Marshalls role in creating solutions for so many of these daunting technical challenges. Many of these projects will lead to sustainable in-space architecture for human space exploration that will allow us to travel to the Moon, on to Mars, and beyond. Others are developing new scientific instruments capable of providing an unprecedented glimpse into our universe. NASA has led the charge in space exploration for more than six decades, and through the Artemis program we will help build on our work in low Earth orbit and pave the way to the Moon and Mars. At Marshall, we leverage the skills and interest of the international community to conduct scientific research, develop and demonstrate technology, and train international crews to operate further from Earth for longer periods of time than ever before first at the lunar surface, then on to our next giant leap, human exploration of Mars. While each project in this report seeks to advance new technology and challenge conventions, it is important to recognize the diversity of activities and people supporting our mission. This report not only showcases the Centers capabilities and our partnerships, it also highlights the progress our people have achieved in the past year. These scientists, researchers and innovators are why Marshall and NASA will continue to be a leader in innovation, exploration, and discovery for years to come

Providing Rational for Further Funding Additive Manufacturing Efforts in the Air Force

Extremely long lead times for legacy aircraft replacement parts often exceed 120 days and cost 3 to 4 times the original price drives a search for alternative manufacturing methods such as additive manufacturing. Currently, the method to procuring a legacy replacement for aircraft such as the C-130 is daunting and at times, impossible. Through a comprehensive knowledge collection of organizational data the Air Force body of knowledge increases and provides actionable data to decision makers which has the potential of dramatically decreasing part wait times and procurement. The proposed, intuitive decision analysis framework mapped out in this research provides relevant direction for potential candidates considering additive manufacturing alternatives within their organizations. As result of this study, interested parties now have an abridged guide to costs, expenses, and challenges of setting up an Additive Manufacturing facility within their establishments

Benchmarking DoD Use of Additive Manufacturing and Quantifying Costs

Additive Manufacturing (AM), or three-dimensional (3D) printing as it is commonly referred to, is a rapidly developing technology that has the potential to revolutionize the way that firms develop and produce parts, as well as how they manage their supply chains. AM allows organizations to print prototypes, parts, tools, fixtures, tooling and a variety of other items at their production location. This can remove long lead times and high inventory levels for one-time or rare items. This research examines current AM use within the military services. Additionally, this study details the costs associated with fielding different levels of AM capability, specifically metal printing, production level polymer printing, and desktop level polymer printing. Finally, this research quantifies the cost of producing a metal part using AM. Ten parts with long lead times were chosen for analysis, and the cost calculated for AM production is compared to the price the Air Force currently pays to procure these parts. Topics for future research into of AM will be presented

Test and Evaluation of Ultrasonic Additive Manufacturing (UAM) for a Large Aircraft Maintenance Shelter (LAMS) Baseplate

Additive manufacturing is an exciting new manufacturing technology that could have application to Air Force Civil Engineer (CE) operations. This research replicates a Large Area Maintenance Shelter (LAMS) baseplate design for ultrasonic additive manufacturing (UAM). Due to production problems the test section was not built as designed. Instead, a smaller block of material was submitted for evaluation. After the UAM build, ultrasonic inspection was conducted to identify anomalies in the test piece. The results of this proof of concept study indicate that UAM is not yet ready for CE expeditionary applications requiring a high degree of mechanical strength. The machine failed to build a baseplate of the same dimensions as would be required for use in the field. Further, the test specimen produced using UAM had a substantial number of anomalies throughout the entire y-axis of orientation. As the technology continues to improve, UAM may produce welds of sufficient strength to support expeditionary structural applications

Understanding the Norwegian additive manufacturing market: Its attractive aspects, limitations, potential and future opportunities within a circular framework.

The main objective of this thesis was to shed light on the current additive manufacturing market today in Norway, and from there conduct simulations for expected demand level and profitability in a powder production. The AM market in Norway was emphasised through a specific focus on attractive aspects, limitations, opportunities and perceived barriers to entry for both the technology and the market. The research was divided into two types, both quantitative and qualitative research. The AM market of Norway and research questions regarding it was highlighted through a qualitative analysis, where relevant actors in the AM market was interviewed through the use of semi-structured interviews. This was then directly compared to relevant literature on the area in order to find any common reoccurring themes. A specific case study on powder production in Norway was conducted in its own quantitative analysis, simulating expected demand and growth for the next five years

A Guide to Additive Manufacturing

This open access book gives both a theoretical and practical overview of several important aspects of additive manufacturing (AM). It is written in an educative style to enable the reader to understand and apply the material. It begins with an introduction to AM technologies and the general workflow, as well as an overview of the current standards within AM. In the following chapter, a more in-depth description is given of design optimization and simulation for AM in polymers and metals, including practical guidelines for topology optimization and the use of lattice structures. Special attention is also given to the economics of AM and when the technology offers a benefit compared to conventional manufacturing processes. This is followed by a chapter with practical insights into how AM materials and processing parameters are developed for both material extrusion and powder bed fusion. The final chapter describes functionally graded AM in various materials and technologies. Throughout the book, a large number of industrial applications are described to exemplify the benefits of AM