1. 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
DISTRIBUTION A. Approved for public release: distribution unlimited.

3. 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.

4. 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.

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. Next Steps Provide us feedback! Ask questions.
Unclassified
DISTRIBUTION A
Provide us feedback! Ask questions.
Post all industry day briefs on registration website
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

15. Backups
Unclassified
DISTRIBUTION A 15

16. 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