NDLI: Additive manufacturing of Ti-6Al-4V alloy components for spacecraft applications

Content Provider	IEEE Xplore Digital Library
Author	Rawal, S. Brantley, J. Karabudak, N.
Copyright Year	2013
Description	Author affiliation: Lockheed Martin Space Syst. Co., Denver, CO, USA (Rawal, S.; Brantley, J.) \|\| Corp. HQ, Lockheed Martin Corp., Bethesda, MD, USA (Karabudak, N.)
Abstract	In the last two decades, there have been significant advancements in the field of additive manufacturing of Ti-6Al-4V alloy and other metallic components for aerospace applications. Generally, metallic brackets used in spacecraft applications are machined from the bulk-rolled or extruded products of the specific alloy. Using Arcam's electron beam melting-based (EBM) additive manufacturing process, several Ti-6Al-4V alloy brackets were produced, finish machined, and tested to determine their mechanical properties compared to the bulk alloy. This paper describes the use of several EBM-processed Ti-6Al-4V brackets on the Juno spacecraft. Initially, the three-dimensional (3-D) CAD model of each of the bracket drawings was developed to include slightly excess surface layers for machining to a smooth surface finish. Multiple parts were built simultaneously in the available chamber size. Preliminary cost and benefit analysis was also performed to assess the merit of using additive manufacturing for future spacecraft components. Under the same EBM processing conditions, multiple Ti-6Al-4V rod specimens were built to prepare the subscale test specimens for mechanical property measurements. Results of these tests indicated that the average material properties were quite comparable to the wrought alloy. Each of the manufactured parts was inspected using a nondestructive test method to ensure the quality of the finished product. A few component-level destructive tests validated that the component had adequate margin of safety to survive operational load conditions. Based on these results, several Ti-6Al-4V brackets were used on the Juno spacecraft which was launched in August 2011. Successful insertion of EBM-processed parts should pave the way for the use of Additive manufacturing in future spacecraft components.
Sponsorship	IEEE Aerosp. Electron. Syst. Soc.
Starting Page	5
Ending Page	11
File Size	3053132
Page Count	7
File Format	PDF
ISBN	9781467363952
e-ISBN	9781467363969
DOI	10.1109/RAST.2013.6581260
Language	English
Publisher	Institute of Electrical and Electronics Engineers, Inc. (IEEE)
Publisher Date	2013-06-12
Publisher Place	Turkey
Access Restriction	Subscribed
Rights Holder	Institute of Electrical and Electronics Engineers, Inc. (IEEE)
Subject Keyword	Industries Annealing Powders Semiconductor lasers spacecraft components Wires metal additive manufacturing titanium alloy brackets Laser beams electron beam melting mechanical properties Periodic structures
Content Type	Text
Resource Type	Article

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1	Ministry of Education (GoI), Department of Higher Education	Sanctioning Authority	https://www.education.gov.in/ict-initiatives
2	Indian Institute of Technology Kharagpur	Host Institute of the Project: The host institute of the project is responsible for providing infrastructure support and hosting the project	https://www.iitkgp.ac.in
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4	Project PI / Joint PI	Principal Investigator and Joint Principal Investigators of the project	Dr. B. Sutradhar bsutra@ndl.gov.in Prof. Saswat Chakrabarti will be added soon
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