March_2022_AMP_Digital

A D V A N C E D M A T E R I A L S & P R O C E S S E S | M A R C H 2 0 2 2 2 4 C ertified parts that are additive- ly manufactured (AM) using laser powder bed fusion (L-PBF) tech- nology are already in flight in aerospace and defense applications. As these in- dustries continue to innovate, they are encouraged by the high quality of 3D-printed parts made with titanium, aluminum, and nickel-based alloys— and are asking AM equipment makers to qualify an ever-broadening roster of other materials (Fig. 1). It’s perhaps no surprise that aero- space and defense have been the primary drivers of advancements in ad- ditive manufacturing. The benefits of the technology are tangible and com- petitive: novel designs that couldn’t be manufactured any other way, light- er-weight components with consoli- dated parts and optimized topologies, often greater strength and durabili- ty than conventionally manufactured parts, and significant performance boosts in aircraft engines, heavy-lift rockets, drone turbines, and satellite launchers. But qualifying a particular met- al alloy for L-PBF can be a highly exact- ing journey. While the specifications for conventional manufacturing methodol- ogies of the same alloy have existed for years (through SAE International, ASTM, or similar regulatory bodies world- wide), the number of specifications for L-PBF have been sparse, and have hin- dered its adoption. As L-PBF has ma- tured, specifications have started to be issued with the participation of regulatory agencies, aerospace OEMs, and L-PBF machine producers. This has been critical for the continued, success- ful adoption of AM in aviation and aero- space. While industry creates specs and standards for the materials being used in production today, L-PBF equipment manufacturers are paying keen atten- tion to customer requests and overall QUALIFYING MATERIALS USING LASER POWDER BED FUSION FOR ADDITIVELY MANUFACTURED AEROSPACE COMPONENTS Ahead of formal certification, many advanced metals have been qualified for 3D printing, allowing for the creation of previously impossible aerospace parts including for the hypersonic environment. TECHNICAL SPOTLIGHT Fig. 1 — Metal powder cloaks a part on an AM build platform after 3D printing.