FAA Prgram Update n By: Rbert Grant Date:
Outline State f (AM) What Is AM Challenges T Be Addressed Examples f Risk Factrs fr AM Surces f Variability Regulatry Requirements Recent FAA Activities invlving AM Summary 2
State f (AM) Cmmnly knwn as 3D-Printing AM use is rapidly expanding and is being intrduced int service thrugh TC prgrams and design changes Many majr OEM s have annunced publically that their new aviatin prducts will have sme AM parts (metallic) Thermplastic AM parts have been utilized fr years in multiple aircraft Visin is that AM will be widely used within the next 5-10 years. 3
State f, cnt Additive manufacturing is the new frntier. It has taken the shackles ff the engineering cmmunity, and gives them a clean canvas Mr. David Jyce, GE Aviatin President and CEO "Metal parts frm sme AM systems are already n par with their cast r wrught cunterparts. As rganizatins qualify and certify these and ther materials and prcesses, the industry will grw very large Surce: Whlers Reprt 2012 We are n the cusp f a stepchange in weight reductin and efficiency prducing aircraft parts which weight 30 t 55 %, while reducing raw material used by 90 % Mr. Peter Sander, Airbus "3D printing pens up new pssibilities, new design space Thrugh the 3D printing prcess, yu're nt cnstrained [by] having t get a tl in t create a shape. Yu can create any shape yu like. Dr. Henner Wapenhans, Rlls-Ryce Head f Technlgy Strategy 4
What Is (AM) (AM) -- A prcess f jining materials t make bjects frm 3D mdel data, usually layer upn layer, as ppsed t subtractive manufacturing methdlgies (Ref: ASTM F2792 12a) By Surce f Material: Pwder vs. Wire By Surce f Energy: Laser vs. E-Beam 5
AM Challenges T Be Addressed tp five Limited understanding f acceptable ranges f variatin fr key manufacturing parameters Limited understanding f key failure mechanisms and material anmalies Lack f industry databases / allwables Develpment f NDI prcedures with accept/reject criteria Lack f industry specs and standards Other cnsideratins OEM-prprietary vs. cmmdity type technlgy path Lw barrier t entry fr new (inexperienced?) suppliers 6
Examples f Risk Factrs fr AM Surface Quality ver 100 prcess parameters identified Prcess Cntrls Micrstructure Variability Pwder Cntrl HIP Effectiveness Many Mre Identified by Experts 7
Surce f Variability - Examples Pwder/Wire specificatin Pwder Blending and/r recycling Parts in a Build Specimens built with parts Part Feature Orientatin Machine sftware versin Machine Prcess Parameters Surface finish Layer Thickness Pst build peratins Material characterizatin 8
Federal Regulatins The Regulatins are: Part f Title 14 f the Cde f Federal Regulatins (CFR). Prescribed by the (FAA) gverning all aviatin activities in the United States. Regulatins that apply t the certificatin f specific prducts (aircraft, engines and prpellers): Part 21 Certificatin Prcedures fr Prducts and Parts Part 23 Airwrthiness Standards: Nrmal, Utility, Acrbatic and Cmmuter Airplanes Part 25 Airwrthiness Standards: Transprt Categry Airplanes Part 27 Airwrthiness Standards: Nrmal Categry Rtrcraft Part 29 Airwrthiness Standards: Transprt Categry Rtrcraft Part 33 Airwrthiness Standards: Aircraft Engines Part 35 Airwrthiness Standards: Prpellers 9
FAA Regulatins 2X.603 Materials. The suitability and durability f materials used fr parts, failure f which culd adversely affect safety, must: Be established n the basis f experience r tests Meet apprved specificatins that ensure their having the strength and ther prperties assumed in the design data; and Take int accunt the effects f envirnmental cnditins, such as temperature and humidity, expected in service. 10
2X.605 Fabricatin methds. FAA Regulatins, cnt The methds f fabricatin used must prduce a cnsistently sund structure. If a fabricatin prcess requires clse cntrl t reach this bjective, the prcess must be perfrmed accrding t an apprved prcess specificatin. Each new aircraft fabricatin methd must be substantiated by a test prgram. Publically available AM material and prcess specificatins have nt been used in FAA apprved metallic AM parts. Cmpany-develped prprietary specificatins 11
FAA Regulatins, cnt 2X.613 Material strength prperties and design values. Material strength prperties must be based n enugh tests f materials meeting specificatins t establish design values n a statistical basis. Design values must be chsen t minimize the prbability f structural failure due t material variability. Design values must assure material strength with the fllwing prbability: Single lad paths, where failure wuld result in lss f structural integrity f the cmpnent, 99% prbability with 95% cnfidence. Redundant lad path, 90% prbability with 95% cnfidence statistics 12
Recent FAA Activities in AM AMNT ( Natinal Team) chartered by FAA management (Oct 2015). Includes representatives f fur Directrates, Flight Standards, Tech Center, MIDO, Chief Scientists, and HQ Develpment f agency s AM Radmap AM Mem (FAA Internal Jun 2015) AM Issue Papers (Directrates) Jint FAA-USAF Wrkshp (CSTA Wrkshp) n AM held in September 2015 Benchmarking f OEMs in prgress 13
Recent FAA Activities in AM, cnt We are wrking with ther gvernment agencies, standards rganizatins, academia, and industry including: SAE, ASTM AIA (Kick-ff meeting held last mnth) FAA Chief Scientist supprting America Makes Develping plicy fr AM parts with failure cnsequence f minr and belw. Develping AM checklists fr use by FAA certificatin engineers and inspectrs. 14
Summary The use f AM in aviatin is rapidly expanding. As industry gains experience with AM, the level f part criticality is expected t increase. Key AM cnsideratins include: Identificatin and characterizatin f key failure mdes and anmalies Cntrl f Significant prcess variables fr AM by prcess specificatins t ensure that sund structure can be cnsistently prduced. Creatin f public specificatins fr AM materials and prcesses Develpment f design values QA, Prcess Mnitring and NDI methds The FAA AM Natinal Team will cntinue t engage with ther gvernment agencies, standards rganizatins, academia, and industry t ensure the safe intrductin f AM parts int service. 15
FAA Cntact Infrmatin Rbert Grant Aerspace Engineer Design, Manufacturing, & Airwrthiness Divisin Email: rbert.grant@faa.gv 16
Infrmatin Slides 17
FAA Plicy fr AM parts with failure cnsequence f minr and belw Minr Failure Cnditins: Fr the purpses f this plicy, minr failure cnditins d nt significantly reduce aircraft r engine safety and invlve crew actins that are well within crew capabilities. Minr failure cnditins may include a slight reductin in safety margins r functinal capabilities, a slight increase in crew wrklad (e.g. rutine flight plan changes), r sme physical discmfrt t ccupants (e.g. passengers and flight crew). 18
PMA / TSOA Applicants may receive Prductin Apprval (PMA), Authrizatin t build TSO parts (TSOA). PMA (Part 21, Subpart K) Is a cmbined design and prductin apprval fr mdificatin and replacement articles. It allws a manufacturer t prduce and sell these articles fr installatin n type certificated prducts. TSOA (Part 21, Subpart O) It allws a manufacturer t prduce and sell these articles that meet minimum perfrmance set by Technical Standard Order (TSO). Applicant still must shw that PMA/TSO cmpnent meets the TC requirements prir t installatin 19
33.15 Materials. FAA Regulatins, cnt The suitability and durability f materials used in the engine must: Be established n the basis f experience r tests, and Cnfrm t apprved specificatins that ensure their having the strength and ther prperties assumed in the design data. 20
FAA Regulatins, cnt 35.17 Materials and manufacturing methds. The suitability and durability f materials used in the prpeller must: Be established n the basis f experience, test r bth; and Accunt fr envirnmental cnditins expected in service. All materials and manufacturing methds must cnfrm t specificatins acceptable t the. The design values f prperties f materials must be suitably related t the mst adverse prperties stated in the material specificatin fr applicable cnditins expected in service. 21