Fusion and/or solid state additive manufacturing for aerospace applications

Abstract Fusion-based metal additive manufacturing (AM), growing at a double digit rate over the past decade, and escalating, has become the norm for the first look of how to replace the standard subtractive processing to produce metallic componentry for aerospace applications. There are multiple power process of laser, e-beam, and plasma transferred arc to produce the energy beam that melts wire and/or metal powder into a pool that through computer aided design process control builds metals layer-by-layer into near net shape componentry free of a requirement for tooling. Columnar growth, distortion, and defects from fusion AM play a major role in building shapes to tolerances and certifying quality suitable for aerospace applications. Real-time monitoring of the build through multiple wavelength technology, the output of which feeds algorithm systems that real time control the AM system, provides history of the build. The use of a subtractive capability to in-situ real time remove detected defects can provide a histogram of the build that, combined with post nondestructive testing and proper heat treatment, can provide certification the AM-produced component meets aerospace requirements. Solid state nonmelt friction stir processing (FSP) of metals has demonstrated substantial freedom of distortion, producing very fine isotopic grain structures exhibiting properties greater than wrought or AM produced material. FSP can be coupled with fusion AM to produce certifiably aerospace quality metal componentry exhibiting exemplary properties. Aerospace manufacturing is being transformed by AM, which is becoming the new norm.