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UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited.

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UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited.sme.org/smartmfgseries

Additive Manufacturing Repair within the ARMY

Mr. Michael NikodinovskiU.S. Army RDECOM-TARDEC

Warren, MI


UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited.Disclaimer: Reference herein to any specific commercial company, product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or the Department of the Army (DoA). The opinions of the authors expressed herein do not necessarily state or reflect those of the United States Government or the DoA, and shall not be used for advertising or product endorsement purposes.




Army: S&T Performing Organizations

RDECOMResearch,

Development &

Engineering

Command

AMRDECAviation & Missile

Research,

Development &

Engineering

Command

ARLArmy Research

Laboratory

Armaments Research,

Development &

Engineering

Command

Communications-

Electronics Research,

Development &

Engineering

Command

Edgewood Chemical

Biological Center

Natick Soldier

Research,

Development &

Engineering

Command

Tank-Automotive

Research,

Development &

Engineering

Command

ECBC NSRDECCERDEC TARDECARDEC

Medical

MEDCOMArmy Medical

Command

Personnel

G-1HQDA, G-1

Personnel

Infrastructure/Environmental

USACEArmy Corps of

Engineers

Materiel

AMCArmy Materiel

Command

Strategic

Missile Defense

SMDCArmy Space & Missile

Defense Command

Test & Evaluation

ATECArmy Test &

Evaluation Command

71.9%*9.9%* 14.3%* 2.3%*1.6%*

* Percent of S&T core program executed




S&T in RDECOM

XM25 Counter Defilade Target Engagement SystemTranslational Neuroscience

ARL

RDECs

PMs/PEOS

Face-Gear Technology for Block III ApacheMRAP Armor MEMS TBI Sensor

Discovery Innovation Advanced Development

Engineering & Production

Support to Warfighter




Current RDECOM AM Capabilities

AMRDEC

Processes • Fused Deposition Modeling• Vat Polymerization• Polymer Jetting• Dimatix

Materials

Applications

• ULTEM*, ABS (Acrylonitrile Butadiene Styrene), PLA (polylactide)

• Prototypes, electronics

Army Research Lab (ARL)

Processes • Polymer extrusion• Vat Polymerization• Powder Bed Metal• InkJet /Aerosol Jet• Micro Pump Deposition• Cold Spray

Materials

Applications

• Polymers, Metals, Ceramics & materials for printed electronics

• Research

CERDEC

Processes • Polymer jet printing

Materials

Applications

• photopolymer• Engineering

development prototyping

ARDEC

Processes • Polymer Extrusion, Vat Polymerization, Powder Bed Polymer and Metal Fusion

Materials

Applications

• Epoxy, ABS, PLA, Wax, 17-4 SS, 300 Maraging Steel, Nylon, Casting molds, Prototypes

TARDEC

Processes • Direct Metal Deposition• Fused Deposition Modeling• Selectively depositing liquid

binding material

Materials

Applications

• Fe, Co, Ni, Ti, ABS, PLA, Wax• Coating / part repair, 3D

printing, & Multi-material joining

ECBC

Processes • Polymer extrusion• Vat Polymerization• Powder Bed • Polymer & Binder Jetting

Materials

Applications

• ABS, ULTEM*, PC, PPSF (polyphenylsulfone), Nylon 11, Nylon 12, Steels, Cobalt Prototypes, unique fixtures, end-use items, Tooling

NSRDEC

Processes • Polymer jet printing• FDM

Materials

Applications

• photopolymer• Engineering

development prototyping




AM can impact all Army systems

Repair Parts

Weight Reduction

Vehicles

Subsystems

UAVs, UGVs

Missiles/Munitions:

Soldier Protection




It’s all about sustainment




Military Considerations• DOD heavily investigating the utilization of Printed Electronics

in weapon systems.

• Transportation, storage, and operational environments must be considered.

• DOD represents unique environment for printed electronics utilization.

- High G loads

- Extreme Temperature and Humidity ranges

- High shock and vibration loads

- Extended Periods of dormancy (+20 Years)

- Remote locations

• Limited data for failure mechanisms, failure rates, reliability, survivability.

• Need for high reliability devices in DOD applications.




In-Field AM Applications• Point-of-use manufacturing / Remanufacturing for non-critical

parts

• Establish library of parts “Digital Catalogue” of Additive Manufactured Parts for field sustainment

• Reduces logistics burden and lead-time for spare parts

Easy to Print controls (Touch Screen)

Mini Track Bot BracketDesigned as an ultra portable bot forcamera surveillance in any terrain.Operated by a small touch screencontroller with adequate range for thesoldier to standoff at a safe distance.

Mobile Parts Hospital #2 (Portable Unit)




Additive for Reclaim / Repair• Reduces maintenance and repair costs

• Supports diminished supply base issues

• Extends useful life of end use parts

• Increase sustainment capabilities

• Reduces lead-time for spare parts

• Adds additional procurement options to mitigate future issues

• Offers part repair at point of need (organic base or in theater)

• Tooling Repair: Dies & Inserts

• Additional capabilities for the organic base (Depots & Arsenals)

• Portable units offer in-field repair capabilities for critical parts

• Initial capability will lead to adoption of other AM technologies




Technologies: Direct Laser Deposition

Available at TARDEC, Benet Labs (ARDEC), & Anniston Army Depot

DLD process creates parts by focusing a

laser beam at metallic powders so that it

deposit as molten pool of metal onto a

metallic work piece.

ADVANTAGES

• Deposited materials identical to original

or can provide enhanced

corrosion/wear with alloys

• Can be used on any weldable material

such as stainless steels, nickel alloys,

Titanium, cobalt alloys, copper nickel

alloys, and tantalum.

• Cost and process time reduction




OPTOMEC LENS: Hybrid Vertical Mill

Fadal Vertical Mill Upgraded with LENS

Print Engine

Specs

• 1990s Fadal

• Laser Safe Hood & Glass

• Dual Powder Feeder Cart

• LENS Print Head on Vertical Stage

• IPG 1kW Laser

• One Controller




Technologies: Cold Spray

Available at ARL & Anniston Army Depot

Cold Spray using high pressure gas (He

or N2) to propel fine powder particles

through a De Laval rocket nozzle at a

substrate. The particles adhere to a base

surface upon collision with that surface.

ADVANTAGES

• Uniform microstructure

• No high temperatures, dangerous

gases or radiation, and no chemically

aggressive wastes.

• Portable equipment available for field

service application

• Wide range of metallic and ceramic

materials




HistoryAM as a repair process has been around in the ARMY for at least 20 years

Key Advancements

• Early 2000’s: DLD technology integration at nonprofits and Depots

• 2001: Cold spray lab established at ARL

• 2002: First successful application of AM repair: M1 Abrams Platform

• 2003: Several fielded parts

• 2005: Integration of DLD into Mobile Parts Hospital

• 2006: DLD integration at Benet Labs (ARDEC)

• 2008: SBIR efforts to advance laser deposition technologies

• 2014: Technology integration at TARDEC

• 2015: Cold Spray process integration at Depots




Problem/Challenge:

• Replacement cost increase

• Readiness became a substantial issue for M1 Abrams fleet.

Solutions/Results:

• Use AM to dimensionally restore worn surfaces.

• Surfaces were machined undersize, built up with a wear resistant material

and machined back to drawing dimensional requirements.

Benefit/Impact:

• Provided additional procurement option during transition to new engine

OEM.

• Replenish the supply system with new parts, replacing ones that have

multiple repairs.

• Many parts were successfully repaired over two decades ago, currently

equipment is idle.

Case Study Part: Turbine Eng. Components

Weapon System: M1 Abrams Platform

Cost Savings: Average 50% Estimate

DLD Case Study




DLD Case Study Case Study Part: CTI Spindles

Weapon System: M911 & M1070 (HET)

Cost Savings: 90% Estimate

Problem/Challenge:

• Supply issues: 46 Week Lead time

• 20+ Vehicles left inoperable waiting for replacement parts

Solutions/Results:

• Worn surfaces were machined undersize, built up with a wear resistant

material and machined back to drawing dimensional requirements.

Benefit/Impact:

• Forged and machined parts such as these require months to obtain a

second source

• Repair process provides readiness options regardless of process cost.

Savings

• Returned to service (37) Spindles

• New: $7500, 46 Weeks vs. Repaired: $750, 9 Weeks Worn Spindle Laser Deposit




Cold Spray EffortRepair of Aircraft Titanium Hydraulic Line

Chafing

~ 0.2 x 0.1 in.

Repair by cold sprayed titanium




Mg Housing Coated with CP-Al

Masked & Grit Blasted

Flange Area Filled with -Aluminum

Cold Spray Effort




DLD Technology Transition SetbackWhile the use of Additive Manufacturing for repair has been demonstrated within the Army for over two decades, its current use is minimal

Limited use can be attributed to the following:

• Lack of organizational structure at RDT&E and program communities to implement changes

• No common process within the Army for submission-evaluation of repair procedures

• No commercial or Mil Standard during a time when the technology was still evolving

• Customers not willing to change from current practices

• Limited interaction between the different Army and DoD communities




Adopting Laser AM Repairs- New EffortsAs of FY16, the Army’s RDT&E community is currently funding a number of AM repair efforts. All with the following objectives:

• Cross-organizational support (RDECOM, Depots, & Program offices)

• Common data collection and database of AM repair processes

• Development of a common Army process for submission-evaluation of repair procedures

• Common test procedures for validating repair process

• Evaluation of M&S software to reduce upfront validation costs

• Update MIL-STD-3049 and/or support a commercial spec

• Educating people who are outside of the AM community

MIL-STD-3049: Materials Deposition, DDM: Direct Deposition Of Metal For Remanufacture, Restoration

And Recoating (Released September 2013)

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