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

www.alphastarcorp.com
www.raytheon.com

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 188-page issue includes articles and reports on:

  • From rapid prototyping to rocket engines: The evolution of 3T Additive Manufacturing
  • Natural resources and national strategies: How metal Additive Manufacturing is taking off in Australia
  • Scalmalloy® is too expensive and design optimisation only makes sense in aerospace. True or false?
  • Safety management in metal Additive Manufacturing: Observations from industry
  • Senvol: How machine learning is helping the U.S. Navy optimise AM process parameters and material performance
  • Understanding build failures in Laser Powder Bed Fusion: An overview
  • MAMC2018: Vienna hosts ASMET’s third Metal Additive Manufacturing Conference
  • Euro PM2018: The processing and properties of additively manufactured aluminium alloys
  • > More information

Latest news

    E-newsletter

    Sign up to our e-newsletter, sent weekly to AM professionals and end-users around the world. We'll also let you know each time a new issue of Metal AM magazine is available.

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:
    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news
    All past issues are available to download in PDF format, in either single page format or as double-page “spreads” for viewing on large monitors. All downloads are free of charge. Go to archive...

    Connect with us

    Visit our social media channels and sign up to our e-newsletter