Laser wire deposition of a large Ti-6AI-4V space component the methodology for creating a functional Ti-6Al-4V satellite part using LWD additive manufacturing is detailed

Abstract

Additive manufacturing (AM) is an attractive solution for the aerospace industry to reduce cost processing, lead times, and material waste. Laser wire deposition (LWD) is a particular type of directed energy deposition (DED) process that can be used for AM applications. The main advantages of using LWD include large working envelopes, high deposition rates, and high-quality parts. This study took advantage ; of the extensive knowledge in the manufacturing of deposition processes and welding metallurgy provided by Liburdi Automation Inc. to print a large Ti-6AI-4V space component with different wall thicknesses. A LAWS 1000 automated welding system associated with multiple degrees of freedom was selected for this case study. The selected part, when fabricated using machining, had a buy-to-fly ratio (BTF) of 30.8. The AM methodology reduced this BTF to 3.2. This paper presents the undertaken methodology for this case study. The manufacturing strategy is also presented, followed by various nondestructive examination procedures used to control part compliance with the tech-nical drawing requirements for postdeposition heat treatments. Destructive examination, including the investi-gation of the typical microstructure that developed within the part, and the mechanical properties of representative sections of the part were performed. Finally, the machining strategy to the drawing requirements of the part was presented based on previous findings.