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ICME Development of Ferrium N63 Gear and Bearing Steel
AeroMat Presentation, 12 April 2017
p. 1
An Integrated Computational Materials
Engineering Approach to Optimizing and
Designing Alloys Tailored for Additive
Manufacturing
Jeff Grabowski, QuesTek Innovations LLC
Dave Snyder, Jason Sebastian
April 10, 2017
ICME Development of Ferrium N63 Gear and Bearing Steel
AeroMat Presentation, 12 April 2017
p. 2
Ferrium® S53® steel
In flight service on U.S. Air Force platforms A-10, C-5, KC-
135, and T-38 to replace existing corrosion-prone steels.
From materials design to flight in 10 years
Being used for numerous flight-critical components on
SpaceX’s successful Falcon rocket program
Ferrium M54® steel
Navy qualified landing gear hook shank with >2x life vs.
incumbent alloy; cost savings of $3 Million to fleet.
From materials design to flight in 7 years
Ferrium C61™ and C64® steelBeing qualified for next generation helicopter transmission
shaft and gears for U.S. Navy and U.S. Army, replacing
existing steels used for 50 years
QuesTek background: ICME design and commercial
deployment of high performance Ferrium® alloys
NAVAIR Public Release #2014-712
Distribution Statement A- "Approved for
public release; distribution is unlimited"
Ferrium M54 hook shank for T-45 aircraft
Ferrium S53 roll
pin for C-5
aircraft
20% increase in power
density (power to weight
ratio) vs. incumbent
steel
Ferrium C61
rotor shaft for
Boeing Chinook
helicopter
Falcon 9 Launch And Landing
Streak, courtesy of SpaceX
p. 3
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
• Materials challenges in Additive Manufacturing (AM)
• Summary of QuesTek projects using ICME to address challenges, and two case studies:– Design of high performance Al alloys tailored for AM
– Ni AM property uncertainty quantification
• QuesTek ICME-designed materials relevant to AM
• Summary and opportunities in industry
Agenda
p. 4
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
• There is increasing interest in the
development of new alloys specifically
designed for additive manufacturing (AM)
• Adaptation of traditional wrought/cast alloys
to AM processing presents limitations
• Alloy producers, OEMs, government
• Additive manufacturing alloy design
considerations include:
• Rapid heating / cooling / solidification
− Intense residual stresses
− Non-equilibrium microstructures
− Hot tearing, quench suppressibility concerns
• Oxygen tolerance (“gettering”)
• Novel precipitation strengthening concepts
QuesTek ICME approach to AM alloy modeling
and design
QuesTek has established itself as a leader in designing new and
optimizing legacy alloys specifically tailored for AM
p. 5
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
QuesTek ICME-focused projects to resolve materials
challenges in Additive Manufacturing
p. 6
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Two ICME case studies: Al alloy design and Ni property
prediction
p. 7
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Acknowledgement of QuesTek AM project partners:
Funding agencies, OEMs, service bureaus,
p. 8
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Industry need for new Al alloys tailored for AM:
Navy SBIR solicitation (Topic N141-062; Dec, 2013)
Navy problem statement:
To-date, only two traditional aluminum casting alloys have been used
in the AM of aluminum components. However, these alloys were
designed for casting operations in which alloy viscosity and
elemental partitioning during solidification (10 deg/sec) must be
minimized at the expense of strength, ductility, and fatigue
resistance. A new class of alloys is needed to take advantage of the
much faster cooling rates (>1000 deg/sec) and unique processing
condition used during AM.
PHASE III: Transition alloy composition to commercial supply via
OEM, bulk material vendors, or other partnering agreement.
Demonstrate and transition AM process controls and settings to FRC
and other DoD production/maintenance facilities.
p. 9
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
QuesTek ICME-design of Al alloys tailored for DMLS
• Existing Al AM alloys used due to success in
processing, but are low strength (AlSi12, AlSi10Mg)
• AM of high-strength Al alloys (e.g. 6061, 7050)
limited by “Hot Tearing”– Due to high residual stress & sub-optimal solidification behavior
• QuesTek Program Goal: Development of high-
strength, precipitation-hardenable Al alloys
optimized for AM
• One ONR Phase II ending in 2017– Target application helicopter gearbox housings to replace cast Al and Mg
– 1x50 lbs of powder supplied by Valimet
– 2x400 lbs of powder supplied by LPW (UK)
– Additional “final” designs in 2017
• Second NAVAIR Phase I complete, Ph II funding
notified in March, 2017– Target application aircraft structures; equivalency to 7050-T7x
– ~2x100 lbs powder in 2017, followed by larger scale powder lot in early
2018
Comparison of AlSi10Mg and Al-6061
Processed Through DMLSB. Fulcher et.al, 2014 SFF Symposium proceedings
Hot tearing in 6061
processed by DMLS
p. 10
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
• Design concept validation for hot tearing
resistance combined with:
– Strength and SCC (PH-5000 and 7000
series concepts)
– High temperature (2000-concept)
• Cast plates showed successful
elimination of hot cracking, coupled
with high precipitation strengthening
Feasibility Demonstration – DMLS “Bead-on-plate”
tests showed no cracking
Baseline
Alloys
Bead-on-plate trials directly in an EOS M280
Concept
Designs
p. 11
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
QuesTek ICME model integration to enable design of
high performance Al alloys for AM
Region of
combined strength
+ hot tearing
resistance
Computational Optimization between performance
and processing
Integration of material models to visualize trade-off between design
metrics
p. 12
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
AM Uncertainty Quantification of DMLS 718+ DARPA Open Manufacturing
• Microstructure prediction (thermodynamics)
− Phase constitution (including defects)
− Microstructure evolution during process and post-processes
• Solidification, homogenization, grain and precipitate evolution
− Process optimization for maximum performance in DMLS 718+
• Property modeling: YS, UTS (room temp to 1000°F)
− Calibration to DMLS data
− Detailed UQ sensitivity analysis and Accelerated Insertion of
Materials (AIM) minimum property forecasts based on data from two
builds
• Aid in optimizing composition and process tolerances
QuesTek calibration and validation of models using ICME to
predict microstructure and maximize properties of 718+
components produced using DMLS:
p. 13
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Honeywell DARPA Open Manufacturing DMLS 718+
Project scope
Process modeling/
monitoring
Microstructure-
Property Modeling
p. 14
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
QuesTek ICME microstructure evolution modeling
DARPA Open Manufacturing 718+
1
2
3
4
p. 15
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
QuesTek ICME mechanical property predictions
DARPA Open Manufacturing 718+
Mechanistic
Property Models
Property Predictions
(TYS, UTS, RT-1000°F)
AIM Design Allowables
Forecasting
p. 16
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Ferrium C64 steel for aerospace gear applications
Current Army Phase II SBIR
• Army need for high-performance AM gear material in
rapid design / prototype efforts
• No known carburizable steel demonstreated in AM to
date.
• Project focus: Adapt best-in-class Ferrium C64
carburizable steel for AM
• Being qualified by Bell and Sikorsky/Lockheed
FARDS for next gen helicopter gears, allowing
lightweighting
• DMLS and LENS builds demonstrated
• Technical accomplishments:
− Successful atomization of powder
− Successful AM builds (no cracking, low porosity)
− Good response to carburization
− AMS Min tensile properties met (though lower than wrought)
• Technical challenges:
− Carbon loss
− Low ductility due to porosity Need for HIP step
Initial LENS Deposition Trials
p. 17
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
• Originally ICME-designed as casting alloy for US
Army, QuesTek’s Ti alloys have been processed by
EBAM process (Sciaky)
• Designed to have a refined microstructure on
cooling (ideal for AM)
• Increased strength & ductility over cast/EBAM
Ti-64
• Looking for partners to make components using
powder or wire
• Patented in Japan and EU, pending in US
• Joint presentation at AeroMat 2016
QuesTek high performance castable titanium alloys
for AM showed 20% increase in strength
QuesTek’s castable Ti alloys exhibit improved strength-elongation
characteristics relative to Ti-6-4
p. 18
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
• QuesTek has significant experience using ICME to model and design high performance materials for AM across a wide range of materials (Al, Ni, Ti, Fe, W), focusing on:
– Adapting/optimizing legacy alloys for AM
– Modeling of existing materials for AM
– Design and development of new materials for AM
• We would welcome requests from industry / government to using our ICME expertise to:
– Resolve material or quality issues during AM component manufacture or heat treatment
– More quickly (and at lower cost) define expected component-level design minimum properties using Accelerated Insertion of Materials
– Accelerate the qualification of components and ensure highest component performance
– Design new alloys tailored for specific performance requirements
Overall summary and ICME opportunities in AM
p. 19
An Integrated Computational Materials Engineering Approach to
Optimizing and Designing Alloys Tailored for Additive Manufacturing,
April 10, 2017
Questions?
1820 Ridge Avenue, Evanston IL, 60201, USA
www.questek.com
(847) 425-8222
Aziz Asphahani,
Sc.D.
Chief Executive Officer
(847) 425-8227
Jason Sebastian,
Ph.D.
Director of Technology
(847) 425-8241
Jeff Grabowski,
M.S.
Manager of Applications
and Product
Commercialization
(847) 425-8220
Greg Olson,
Sc.D.
Chief Science Officer
(847) 425-8211
Ray Genellie,
M.Sc.
Chief Operations Officer
