Leveraging Additive Manufacturing to Enhance Mission Generation

Transcription

1 AF Life Cycle Management Center Leveraging Additive Manufacturing to Enhance Mission Generation Providing the Warfighter s Edge Debbie Naguy AFLCMC/EZP 22 May 18

2 Laying the Foundation of AM Standardized processes & equipment Certified operators & machines Skilled technicians & engineers Cyber secure, centralized technical data Enterprise Network 2

3 Agile Manufacturing Additive Manufacturing (AM) Today Decentralized Applications Mainly Polymer Based Tomorrow Centralized Applications Future Agile Manufacturing Engineering Application Site Technical Design Package Engineering Drawings Specifications Standards Performance Quality Assurance Reliability Data Modeling Data Feedback Addl part ID Operations Site Limited configuration control Process standardization No digital thread implemented Limited dedicated engineers and operators 50 polymer & 8 metals machines Increase library of qualified parts Expand materials database Standard AF documentation Certified operators/machines Implement digital thread/digital twin Fixtures, tools & stands Vehicles & transportation Weapons systems Global manufacturing network using digital thread Cyber secure parts library 3

4 AM Strategic Implementation Plan (AMSIP) NOW TERM: Establishing AM Capability in Metals and Polymers Establish selective AM capability: depots & MAJCOM backshops Qualify target parts: tools, fixtures, prototypes, non-structural non-critical parts, structural non-aerospace parts Standard AM equipment, training, processes, and tools Scanning & modeling process & tools Develop facility guidelines and post processing NEAR TERM: Expanding AM Capability in Metals and Polymers Expand AM capability: additional weapon system components, expanding across depots, MAJCOMs, and program office engineering Qualify target parts: diminishing manufacturing, non-rotating, non-critical structural aircraft components Demonstrate network capability and cyber secure library Validate AM process controls, material characterization, process parameters, and reproducibility LONG TERM: Expanded AM Network Target opportunities: print anywhere on-demand Target parts: rotating and structural critical aircraft Global network of equipment and processes AMSIP Lays Out The Foundation For Safely Establishing AM Moving Slow To Go Fast 4

5 AM Equipment Across the Air Force 51 Total AM Machines 5

6 Additive Manufacturing Accomplishments Developing foundation to deploy AM technology across the AF with Technical Orders (TOs), process orders, training, and specifications Documented lessons learned and best practices Developed materials database (Ti-6Al-4V, SS 17-4PH, cast grade Al) Includes optimized process parameters for aerospace material requirements Developed Mil-Spec for polymers and Ti-6Al-4V powder Compiled Design for AM (DfAM) guidelines to incorporate in Design Rules Guidebook Printed and qualified parts: C-5 door handle, bell cranks, hatch cover, latrine cover, window reveal, A-frame; B-2 T & Y connectors; Memphis Belle ball turret disk Developed online training for metals AM operators, on-demand maintenance videos, and engineer level DfAM course Way Forward Expand materials database to CoCrMo, IN718, and high strength aluminum Focus on improving fatigue data and reducing residual stress Design for AM, manufacturing, heat treatment, surface finish Implement digital thread/digital twin Expand AF library of qualified parts Develop process for qualifying polymer machines Expand use of AM through communication: 2018 AM TIM, Yammer, Thing of Things Airworthiness qualification of structural components C-17 ducts TF34 pressure regulator Complete final design and print of micro turbine

7 Advanced Technology & Training Center (ATTC) at UDRI (Dayton, OH) Collaboration Space Additive Manufacturing Robotics and Lasers Corrosion Technologies 7

8 Advanced Technology & Training Center (ATTC-Middle Georgia) Warner Robins, GA Hand Held Laser Polymer AM Metals AM Cold Spray Repair Accelerated weather chambers Reverse Engineering Current Status: Initial AM and Corrosion installations Full facility availability Remaining equipment installation Complete hiring Grand Opening 15 May 1 Jun 1 Jul 15 Jul 5 Sep Est

9 Team Approach Community Colleges Universities High Schools Leveraging pockets of excellence to champion the enterprise approach 9

10 Advanced Technology & Training Centers On the horizon... Hill AFB, UT USTAR/ATTC co-location ATTC UDRI in Dayton, OH Est On the horizon... Tinker AFB, OK REACT/ATTC co-location On the horizon... Eglin AFB, FL ATTC ATTC in Middle Georgia Est. Sum 2018 Co-located with centers of engineering experience 10

11 Tomorrow: Centralized Applications Technology & Training Centers Identifying parts Designated engineers, designing, printing, and qualifying parts Non-critical, non-rotating, non-aero and aerospace components Manufacturing Centers Cyber secure library of AM TDP s Qualified equipment, qualified operators utilizing network approach 10 11

12 Future: Agile Manufacturing Global Network Centralized cyber secure library of shared data Strategic technology & training centers qualifying new parts Repair network of manufacturing locations Implementation of digital thread/ digital twin Cyber secure library of AM TDP s 11

13 The Digital Enterprise 13

14 Way Forward 14

15 Speed of Transition Funding Equipment Modeling Real-time monitoring Enhance NDI Limit number of vendors Training Limit types/models of machines Extensive training of engineers/users Leveraging AWB-1015 Qualified Processes Expedite rapid certification & qualification methodologies for faster transition

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