FUNCTIONALLY TAILORED MULTI COMPONENT COMPOSITE STRUCTURES VIA ADDITIVE MANUFACTORING. THE OBJECTIVE OF THIS PROJECT IS TO EXPLORE THE POTENTIAL FOR CREATING A FULLY DENSE MULTI-ALLOY COMPOSITE STRUCTURE WITH A CONTROLLED INTERNAL RESIDUAL STRESS FIELD. THIS WILL BE ACCOMPLISHED THROUGH THE USE OF A ONE-WAY SHAPE MEMORY ALLOY MATERIAL INCORPORATED INTO A STRUCTURAL ALLOY MATERIAL IN A CAREFULLY DESIGNED CO-CONTINUOUS RETICULATED ARRANGEMENT. ADDITIVE MANUFACTURING TECHNIQUES WILL BE USED TO CREATE THE MATRIX COMPONENT (FIGURE 1) USING A STANDARD ENGINEERINGALLOY TI-6AL-4V. THE VOIDS IN THE MATRIX WILL BE FILLED WITH NITINOL SMA POWDER HOT CONSOLIDATED AND SHAPE-SET INTO A FULLY DENSE ARRANGEMENT. THIS COMPOSITE STRUCTURE WILL THEN BE MECHANICALLY WORKED IN ORDER TO INTRODUCE RECOVERABLE PLASTIC STRAIN INTO BOTH THE MATRIX AND THESMA. UPON MEMORY ACTIVATION HEAT TREATMENT THE SMA WILL ATTEMPT TO REVERT TO ITS ORIGINAL SHAPE-SET DIMENSIONS (I.E. CONTRACT) BUT WILL BE CONSTRAINED BY THE TITANIUM ALLOY MATRIX. THE RESULT WILL BE A STRESS STATE SHOWN CONCEPTUALLY IN FIGURE 2. AS CRACKS GENERALLY NUCLEATE AT AFREE SURFACE THE COMPRESSIVE FIELD IN FRONT OF THE CRACK TIP WILL INHIBIT THEIR PROPAGATION. THE STRESS INTENSITY FACTOR (K) IS RELATED TO THE LOCAL STRESS FIELD ( ) BY ! = ! !". CAREFUL DESIGN OF THE STRUCTURE AND THE RESULTANT INTERNAL STRESS FIELD SHOULD ALLOW THE STRESS INTENSITY FACTOR TO REMAIN BELOW THE THRESHOLD VALUE THUS INHIBITING ANY CRACKS FROM GROWING. AND BY THE NATURE OF THE INTERLOCKING ARRANGEMENT OF THE SMA/ALLOY COMPOSITE CORE ANY CRACKS INITIATING IN THIS AREA WILL BE CONTAINED AND ISOLATED FROM THE LOAD BEARING STRUCTURAL LAYERS. FOR THIS INITIAL STUDY DETAILED CHARACTERIZATION OF THE MATERIAL WILL BE CONDUCTED UTILIZING MECHANICAL TESTING ELECTRON MICROSCOPY AND NEUTRON DIFFRACTION. ADDITIONALLY THE APPLICABILITY OF THIS METHOD FOR PRODUCING HIGH STRENGTH HIGH TOUGHNESS AEROSPACE STRUCTURAL COMPONENTS WILL BE EVALUATED ALONG WITH POTENTIAL DUAL USE APPLICATIONS OUTSIDE THE AEROSPACE MARKET.