DISTRIBUTION A. Approved for public release: distribution unlimited. 28 July 2015 Unclassified Quality Metal Additive Manufacturing (QUALITY MADE) Enabling Capability Billy Short Logistics Program Manager QUALITY MADE EC Manager Expeditionary Maneuver Warfare and Combating Terrorism Department billy.short@navy.mil DISTRIBUTION A. Approved for public release: distribution unlimited.

Operational Challenges Unclassified DISTRIBUTION A Operational Challenges Naval Platform and Systems Operational Availability: Decreased platform availability due to an increasing number of part challenges that PMs are facing. Challenges include very long Mean Logistics Delay Time for limited production parts. Lack of commercial interest in low volume complex fabrication work and significant delays in contracting and workflow. Increasing pressure on organic manufacturing capability. As an example, Fleet Readiness Centers (FRCs) produce over 120,000 manufactured items per year. Naval Platform and Systems Total Ownership Cost: High cost for limited production runs to make problem parts; many of those are cast components. This may also include large investments to create special tooling and complex castings.

Operational Challenges Unclassified DISTRIBUTION A Operational Challenges Common Issues Across all Platforms: Aging fleets with severe parts supply issues. Examples: Amphibious Assault Vehicle will be 51 years old at the end of service life & aircraft will have 14,000 hours & designed for 6,000. Higher failure rates; new failure modes; exigent parts demand for critical components Systems down/deadlined for part obsolescence issues; decreasing vendor supply base Increase in components that fail that were never expected to be repaired or replaced Stakeholders/Mission: Depots and FRCs are increasingly making parts to combat these challenges. FRC/Depot mission includes producing parts to improve maintenance efficiency. They need new technologies to enable the reliable and cost-effective production of low volume parts.

AM Injection: Depot Level Maint. Supported by Warfare Centers Unclassified DISTRIBUTION A AM Injection: Depot Level Maint. Supported by Warfare Centers Early transition of ICME / digital design tools Push upgrades Support tooling before parts Installation of sensors on AM machines Technical support to part demonstrations 5

System Boundaries (Assumptions) Unclassified DISTRIBUTION A Not addressing: New AM machines; larger build volumes; faster build rates Performing qualification / certification Cyber Expeditionary use / shipboard integration Need to keep the system manageable 6

FY17-20 Program Goals Unclassified DISTRIBUTION A Enhance quality and reliability of metal additive while addressing key Naval issues Build Naval confidence in material properties for critical metal parts Improved design and quality control tools & processes AM for Naval materials (Ti-64, AlMgSi, SS 316L casting analogs) Material properties better than cast and comparable to wrought Achieve desired volume/geometry Reduce residual stress Improve fatigue properties Support speedy qual/cert 7

FY17-20 Program Goals Improved AM design by gaining Unclassified DISTRIBUTION A Improved AM design by gaining From an enhanced understanding of the correlation of materials properties to AM processes Reduce required redesign iterations before an acceptable design is achieved Establish an upper and lower control limit for critical AM process parameters for a successful build In situ sensors and closed loop process controls to ensure a quality build Control AM process parameters to control microstructure, volume, and geometry Collect build data to support qual/cert 8

Property-Performance EC Synopsis Unclassified DISTRIBUTION A 4 years, FY17-20 Mr. Billy Short, ONR-30 Dr. William Mullins, ONR-33 Dr. Ignacio Perez, ONR-33 Quality AM Parts M&S and Design Tools Quality Control Sensors Process-Structure- Property-Performance Models Controls Casts Start: TRL 4 End: TRL 6 Start: TRL 4 End: TRL 6 Digital Designs & Hardware (parts) Hardware & Knowledge Software & Knowledge Transition Models & Part Designs to NSWC/NAVAIR/Industry Transition Process / Control Suite to FRCs/Depots/Industry Likely Acq Strategy; Defined in BAA (~2) Phase Is (for both ICME & QC), down-selecting to (1) Phase II 9 Unclassified

Integrated Computational Materials Engineering Property-Performance ICME Overview Unclassified DISTRIBUTION A Integrated Computational Materials Engineering (ICME) ----------------- M&S & Design Tools Model the AM process Predict resulting microstructure Predict material properties (stress, fatigue, etc.) Predict part performance Optimize build package Accelerate process acceptance Process-Structure- Property-Performance Models Software & Knowledge (T) Titanium, Aluminum, (O) Steel Alloy Casting Analogues for 2 different AM processes Interface to Closed Loop Controls 10

Closed Loop Overview Thermal cameras & other in situ sensors Unclassified DISTRIBUTION A Melt Pool Illustration Thermal cameras & other in situ sensors Handoff from models Upper and lower limits of processes for a successful build Close the loop to control the build quality Interface to AM Machine Closed Loop Process Controls Titanium Microstructure Sensors Sample Sensor Info Control Algorithms Heating rates Peak temperature Cooling rate Melt pool dimensions & solidification contour Surface shape & roughness Porosity Interface from ICME Hardware & Knowledge Microstructure and mechanical properties are determined by thermal history 11

Quality AM Parts QUALITY MADE EC Unclassified DISTRIBUTION A Quality AM Parts Fabricate quality part demonstrators with Air, Ground, and Sea communities PEO(A) (H-1 Helos) PEO-Land Systems (PM AAA) PEO Ships (LPD-17) 12

Challenges Challenges: Unclassified DISTRIBUTION A Challenges: Defining the boundaries of the problems and sticking to it (mission creep) Open vs Closed AM architectures ICME across a variety of AM processes and materials Self limiting to (2) processes and (2) threshold material (Al & Ti cast analogs with an option for stainless steel). Getting the physics right to inform the design and build at the optimal level of abstraction Informed by the physics while maintaining computational efficiency, where required Integration / interface between ICME products and Closed Loop Controls Continuing to develop framework to support later rapid qualification and certification in acquisition 13

Next Steps Provide us feedback! Ask questions. Unclassified DISTRIBUTION A Provide us feedback! Ask questions. Post all industry day briefs on registration website https://www.onlineregistrationcenter.com/register.asp?m=4269&c=113 Open ONR website to allow communication to government and teaming Refine Broad Agency Announcement White Papers Downselect & seek full proposals Final selection Initiate contracting actions (up to 12 months) Program start 1 Oct 2016 14

Backups Unclassified DISTRIBUTION A 15

Validation and Verification Requirements Requirements for finished product quality and properties Acceptance Tests Integrated System Demonstration and Validation Specifications, KPPs All Requirements Verified Closed Loop Control System Validation Tests for Closed Loop Control System Design Part Properties Verified Sensor Requirements Sensor Signals Sensor Systems for In-Process Tracking Validation Tests for Sensor Systems for In-Process Tracking Validation Material Microstructure Requirements Processing Parameters Valid Ranges Microstructure Verified System of ICME/ Physics Based Tools Validation Tests for ICME/ Physics Based Tools Architecture Selection Compatibility Verified System Architecture, Machine Interface and Management Algorithm