AlphaSTAR & Raytheon to present ‘Qualification of an AM Missile’ at AMUG 2019

March 4, 2019

March 4, 2019

Collaborating on a US Missile Defense Agency Phase II contract, engineering services and software company AlphaSTAR Corporation, Long Beach, California, USA, and Raytheon, a specialist in defence, civil government and cybersecurity solutions based in Waltham, Massachusetts, USA, have cooperated on a project to predict the Additive Manufacturing Process and Service Loading of an as-built additively manufactured part.

Using an ICMSE framework, and feeding through a building block Verification, Validation and Accreditation (VVA), the teams set out with the goal of identifying part issues before building the component, thus saving time, lowering risk and reducing scrap rate. The programme was co-led by Cody Godines, Structures Group Lead at AlphaSTAR, and Isis Roche-Rios and Alicia Leslie, Senior Mechanical Engineers at Raytheon.

“With the promise that Laser Powder Bed Fusion (L-PBF) has in Additive Manufacturing, there are also major pitfalls – such as: defects, unmet net shape, high warpage, residual stress and surface roughness, void formations and inconsistent density just to name a few. We were able to simulate all of these with the GENOA 3DP tool within the Ansys framework before printing,” stated Godines.

Another key component of a successful build was the prediction of thermal history, material state, and process maps, which are used to predict all important phenomena and regions. “We found that knowing all of this information beforehand sets up for a successful final simulation with multi-objective optimisation of the component and support structure to minimise mass and scrap rate while minimising the pitfalls of AM,” added Leslie.

Leslie and Godines will present the success and further findings of this programme on April 1 in the International Ballroom at the Additive Manufacturing User Group Conference (AMUG), which will run from March 31–April 4, 2019, in Chicago, Illinois, USA.

March 4, 2019

In the latest issue of Metal AM magazine

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Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

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