Rapid Prototyping GOTChA Chart

Transcription

1 Rapid Prototyping GOTChA Chart Goals Effect a 30% reduction in cost and 30% increase in through put, by accelerating the insertion of extant and emerging Rapid Prototyping Technologies Objectives Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part". Fully integrate and automate RP Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%. Provide for the production of aerospace components using Rapid Prototyping processes through the development of standard/general qualification procedures for all aerospace structural and propulsion components that are candidates for manufacture by RP processes Technical Challenges Approaches

2 Technical Challenges: Rapid Prototyping Objective 1 - Process Time Improvement Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part". Fully integrate and automate RP Objective 2 - Component Repair Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%. Objective 3 Expanded Capability Provide for the production of aerospace components using Rapid Prototyping processes through the development of general qualification procedures for all aerospace structural and propulsion components that are 1. Equipment Reliability and Repeatablility 2. Non-metallic component mfg (seals, carbon fiber) 3. Size capacity limits 1. Housing repair - fretting 2. Blade and vane length recovery 3. Gear refurbishment 1. Air worthiness certificate process accelerated and iterative 2. NDE Inspection Stds 3. Std Engr Process Specs and Joint Qualification Stds

3 Technical Approaches: Direct Digital Mfg Objective 1; Objective 2; Objective 3; Objective1 : Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part". Fully integrate and automate RP Objective 2: Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%. Objective 3: Provide for the production of aerospace components using Rapid Prototyping processes through the development of general qualification procedures for all aerospace structural and propulsion components that are Challenge 1: Equipment Reliability and Repeatablility 0-5 Years 1. Develop closed loop process monitoring and control. 2. Develop feedstock specs for quality verification including recycle material properties. 3. Ruggedize equipment for sustained manufacturing demand. Challenge 1: Housing repair fretting 0-5 Years 1. Configure process and equipment for housing repairs. 2. Develop surface prep and deposition techniques to preserve baseline material properties. Challenge 1: Air worthiness certificate process initiate w/ process & product development and apply iterative process 0-5 Years 1. Achieve process certification EBM, WEBM, FDM, etc. to replicate all baseline material properties. 2. Validate the application of analysis to support certification. 3. Investigate an iterative cert process vs full testing.

4 Technical Approaches: Direct Digital Mfg Objective 1; Objective 2; Objective 3; Objective1 : Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part". Fully integrate and automate RP Objective 2: Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%. Objective 3: Provide for the production of aerospace components using Rapid Prototyping processes through the development of general qualification procedures for all aerospace structural and propulsion components that are Challenge 2: Non-metallic component mfg (seals, carbon fiber) 0-5 Years 1. Determine candidate parts and materials compatible w/ DDM. 2. Configure process and equipment for candidate parts. 3. Perform make vs buy analysis. Challenge 2: Blade and vane length recovery 0-5 Years 1. Configure process and equipment for housing repairs. 2. Develop surface prep and deposition techniques to preserve baseline material properties. 3. Establish requirements for blade/vane recovery (GD&T). Challenge 2: NDE Inspection Stds 0-5 Years 1. Identify processes for detecting micro-porosity fatigue. 2. Develop acceptance criteria. 3. Assess application of existing testing equipment to develop NDE data.

5 Technical Approaches: Direct Digital Mfg Objective 1; Objective 2; Objective 3; Objective1 : Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part". Fully integrate and automate RP Objective 2: Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%. Objective 3: Provide for the production of aerospace components using Rapid Prototyping processes through the development of general qualification procedures for all aerospace structural and propulsion components that are Challenge 3: Size capacity limits 5-10 Years 1. Determine the candidate parts and material requirements in the larger size category. 2. Validate process scale up wrt solidification rate, temp distribution, insitu stresses, etc. 3. Assess process and equipment versatility for variable size range. 4. Conduct BCA for candidate parts. Challenge 3: Gear refurbishment 5-10 Years 1. Configure process and equipment for housing repairs. 2. Develop surface prep and deposition techniques to preserve baseline material properties. 3. Verify homogeneous properties of repair zone wrt base metal. Challenge 3: Std Engr Process Specs and Joint Qualification Stds 5-10 Years 1. Determine process criteria wrt process technology and material property requirements base line spec 2. Validate process specs 3. Develop common qualification procedures for new processes/materials. 4. Establish joint gov t/industry working group.

6 Enabling Technologies Process Modeling and Simulation NDE Techniques Material Development