N68335-17-R-0191_SPECIFICATION_RevC.pdf

NAVAIR LAKEHURST

AN ADDITIVE MANUFACTURING (AM) POWDER BLOWN

SYSTEM SPECIFICATION

Naval Air Warfare Center Aircraft Division

Prototype and Manufacturing Division (PMD) Joint Base McGuire-Dix-Lakehurst, New Jersey 08733-5000

PREPARED BY: ________________________________________________

Kyle Cobb, 4.8.8.2

REVIEWED BY: ________________________________________________

Eric Kline, 4.8.8.2

1.0 Scope

1.1 System Overview

Additive Manufacturing (AM), or three-dimensional (3D) printing, fabricates products and components from a digital model via an “additive”, i.e. layered build up, process. AM is being applied in a wide range of industries including defense, aerospace, automotive, medical, and metals manufacturing. Utilizing this capability at NAVAIR Lakehurst will reduce the cost and increase the speed at which products are delivered to the Warfighter by increasing production speed of critical parts, enabling novel designs, decreasing obsolescence, filling critical gaps in the Navy supply system, and reducing the design-to-production timeline by an order of magnitude.

In order to allow the Navy to move beyond the two primary technologies that have been focused on up until this time (Powder Bed/DMLS based technology & Wire Fed based technology), NAVAIR Lakehurst must obtain an AM Powder Blown system. In addition, this technology will allow the Navy to development of repair capabilities that can be expanded across multiple projects and fold into the Enterprise Qualification/Certification Solutions needed to operationalize additive manufacturing solutions. This requirement also includes metal powders, base plates, common consumables as well as logistics support for the AM Powder Blown System including training and maintenance. This equipment shall be required to rapidly produce and repair parts of at least 0.216 cubic meters in size in various materials including but not limited to: Aluminum, Steel, Stainless Steel, Titanium, Cobalt-chromium, and Nickel Alloys. This equipment shall be required to have the capability of connecting to our existing network while meeting all applicable IA requirements.

1.2 Document Overview

This document provides the performance and verification requirements for the metallic AM Powder Blown System.

2.0 Applicable Documents

a) Title 21, Code of Federal Regulations (CFR), Parts 1040, 1040.10, and 1040.11

b) NFPA 70, National Electrical Code

c) UNS A96061, Aluminum 6061

d) UNS S15500, Grade 15-5 PH Stainless Steel

e) UNS S17400, Grade 17-4 Stainless Steel

f) UNS R5640x, Titanium Alloy

g) UNS N06225, Nickel Alloy 625

h) UNS N07718, Nickel Alloy 718

i) UNS N07001, Waspaloy

j) UNS R30006, Stellite 6

k) UNS W73041, Stellite 21

l) ISO 8573, Compressed air, Contaminants and purity classes

3.0 Material, Performance, Hardware, and Software Requirements

3.1 Material Requirements

The AM Powder Blown System shall be capable of printing the following alloy bases:

ferrous alloy, stainless steel, nickel, aluminum, cobalt-chromium and titanium.

3.1.1 Material chemistry

Material chemistry shall be within a specified range of the following materials:

a) Aluminum: UNS A96061 (AL 6061)

b) Stainless steel: UNS 15500 (15-5 PH), UNS S17400 (17-4 PH)

c) Titanium: UNS R5640x (Ti-6Al-4V or “Ti-6-4”)

d) Nickel alloys: UNS N06625 (IN625), UNS N07718 (IN718), UNS N07001

(Waspaloy)

e) Cobalt-chromium alloys: UNS R30006 (Stellite 6); UNS W73041 (Stellite 21)

f) Ferrous alloys: Hardenable to HRc 50.

Tramp elements including sulphur, phosphorus, and lead shall be < 0.050% by weight.

3.2 Functional Requirements

The AM Powder Blown System shall achieve the requirements listed herein for the materials specified in section 3.1.

3.2.1 Work Envelope

The work envelope of the AM Powder Blown System shall support the manufacture of a part of with a volume greater than or equal to 0.216 cubic meters.

The work envelope shall support the manufacture of a cube with a minimum edge length of 600 mm.

3.2.2 Powder Feed Rate

The AM Powder Blown system shall be capable of varying the powder feed rate.

The minimum feed rate shall be less than or equal to 1 g/min. The maximum feed rate shall be greater than or equal to 20 g/min.

3.2.3 Layer Thickness

The AM Powder Blown System shall be capable of achieving a layer thickness less than or equal to .012”.

3.2.4 Variable Spot Size

The AM Powder Blown system shall be capable of varying the spot size diameter.

At a minimum, the following spot size diameters must be obtainable:

• 0.5 mm

• 3.0 mm

3.2.5 Minimum Wall Thickness

The AM Powder Blown System shall be capable of achieving a minimum wall thickness less than or equal to 1 mm.

3.2.6 Part Geometry Features

The AM Powder Blown System shall be able to create parts with a minimum overhang angle of 15 degrees.

3.3 Hardware Requirements

3.3.1 Control

The AM Powder Blown System shall use G and/or M-code based machine Computer Numerical Control (CNC) controls to operate the axes. It is acceptable for the system to use proprietary control software that is capable of meeting all other requirements herein specified.

3.3.2 Number of Axes

The AM Powder Blown System shall be capable of 4-axis motion (X, Y, Z, and Rotate) at a minimum. It is preferable to have a 5th axis capable of tilt.

3.3.3 Laser System

The AM Powder Blown System shall have a high-power 2kW Fiber Laser capable of operating at 500W to 2000W with a chiller.

3.3.4 Deposition Head/Nozzle

The AM Powder Blown System shall have a deposition head with interchangeable nozzles (e.g. 4-nozzle and Co-axial).

3.3.5 Powder Feeder(s)

The AM Powder Blown System shall have at least two powder feeders for continuous operation.

3.3.6 Process Monitoring

At a minimum, the AM Powder Blown System shall have the necessary combination of hardware and software capable to achieve the following:

• View deposition surface

• Deposition head and laser alignment, zoom, focus, and spot-size adjustment

It is desirable for the system to have the necessary tools, such as thermal imaging, to achieve process control.

3.3.7 Equipment Size

Based on the location chosen this equipment shall not exceed the following maximum parameters (see Appendix A for building layout):

Parameter Requirement

Overall Max Size (Equipment) 118”L X 118”W X 114” H

Overall Max Size (including required operating space)

200”L X 144”W X 114”H

3.3.8 Equipment Weight

The weight of the AM Powder Blown System shall not exceed the maximum loading capacity of a 6.5” thick concrete slab.

3.3.9 Cabinet

3.3.9.1 Laser Enclosure

The AM Powder Blown System shall have a Class I Laser Enclosure.

3.3.9.2 Viewing Window

The AM Powder Blown System shall have a laser-safe viewing window.

3.3.9.3 Atmosphere Control

The AM Powder Blown System shall have a hermetically sealed enclosure complete with oxygen and moisture control as well as a gas purification system capable of reaching an atmospheric level less than or equal to 10 ppm to maintain process environment and safety.

3.3.9.4 Antechamber

The system shall have an antechamber 14” minimum in diameter for passing smaller parts into the enclosure.

3.3.9.5 Parts Handling

The system shall have a sealed door with glove ports or box.

3.3.10 Operational Environment

The AM Powder Blown System shall operate in an environmentally controlled location meeting the following conditions:

Operational:

a) Temperature: 68°F to 85°F

b) Max. 60 % relative atmospheric humidity Storage:

a) Temperature: 0°F to 100°F

b) Max. 80 %, Relative humidity non-condensing

3.3.11 Electrical Power Requirements

The AM Powder Blown System shall be able to operate with the available power as listed:

- The AM Powder Blown System need not use all of these options; this is what will be available.

a) 400 V 3~/N/PE

b) 220 V 3~/N/PE

c) 220 VAC

d) 110 V AC

Voltage fluctuations: +6 % to -10 % Frequency: 50 / 60 Hz Max Nominal power: 15 kW Current consumption (max.): 50 A

All electrical connections shall comply with NFPA 70 Class II, Division 1, Group E standards.

3.3.12 Cooling Water

Cooling water systems shall be closed loop and shall conform to all other requirements of the system.

3.3.13 Compressed Air

If required, the AM Powder Blown System may utilize externally provided compressed air. Compressed air shall be provided by the government with a minimum flow rate of 15 cfm at 7 bar to the chosen location. The quality of the compressed air shall be in accordance with ISO 8573.

3.3.14 Nitrogen

If required, the AM Powder Blown System will be required to generate its own nitrogen. Any additional hardware required to perform the nitrogen generation shall conform to all other requirements of the system.

3.3.15 Argon

The AM Powder Blown System may utilize externally provided argon. Argon shall have a minimum flow rate of 4 cfm at 5.5 bar.

3.4 Software Requirements

3.4.1 Supporting Software

Any and all software required to set up and complete a build shall be provided. This shall include but is not limited to software needed to:

a) Orient parts within the work envelope

b) Import and convert STLs to a format readable by the AM Powder Blown

System

c) Process simulation

d) Load tool code and operate AM Powder Blown system

e) Modify AM Powder Blown System settings

f) Event logging

g) Facilitate monitoring of builds

The AM Powder Blown System software shall allow operators to have the ability to change material parameter sets including laser parameters for all materials specified by Section 3.1.

3.4.2 Computer

All required software shall run on a computer meeting or exceeding the following specification:

- OS .........................Windows 7

- Processor ...............2 GHz

- RAM .....................8 GB recommended

- Graphic card .........1 GB

- Network interface .RJ45/100BaseTX

- Network protocol ..TCP/IP

- Drives....................CD-ROM

3.5 Supporting Documentation

The following documents shall be supplied with the AM Powder Blown System:

a) Operation Manual

b) Maintenance Manual

c) Installation Manual

4.0 Operation requirements

The AM Powder Blown System shall allow the following operations to be completed within the allotted time limits:

Operation Operator Time Machine Time

Purging build chamber from atmospheric conditions to build conditions 5 minutes 4 hours

Remove completed build and start a new build (including chamber cleaning and material change from stainless steel to titanium)

8 man hours 1 day

Preventative maintenance actions 4 man hours 1 day

5.0 Safety Requirements

1.1. The AM Powder Blown System shall conform to safety requirements as outlined in reference 2.0.a): Title 21, Code of Federal Regulations (CFR), Parts 1040, 1040.10, and 1040.11

1.2. The AM Powder Blown System shall have emergency stop latching switches. At a minimum, emergency stop switches shall be available in the following locations:

a) Mounted to the AM Powder Blown System

b) Wall mountable with wire tether no less than 30ft in length.

1.3. The AM Powder Blown System shall have oxygen sensors for monitoring the oxygen saturation within the build chamber. An output signal of this sensor reading shall be made available to an external device. Instructions for interpreting this signal shall be provided.

1.4. The AM Powder Blown System shall provide an output signal indicating the system’s current status. Instructions for interpreting this signal shall be provided. The following status indications shall be available at a minimum:

a) Machine Idle (Normal atmospheric conditions inside of chamber)

b) Machine Purging Oxygen

c) Current atmospheric level

d) Machine Running (Laser in operation)

e) Machine Fault (Operator intervention required)

f) Emergency Stop

6.0 Verification

6.1 Requirement Applicability

The basic objective of verification is to ensure compliance with the applicable requirements of Sections 3, 4, and 5.

6.2 Required Verifications

For every requirement paragraph in the specification, a corresponding verification and verification method is given in Section 6.

6.3 Verification Requirements Matrix

Table 6.1-1 below lists the requirements paragraphs above and the corresponding required verification from Section 6 below. These verification methods are defined in Table 6.2-1 below.

Table 6.1-1 Verification Requirements Matrix

ITEM DESCRIPTION PARAGRAPH

NUMBER

Preferred Verification method

2nd Verification method

3rd Verification method

4th Verification method

5th Verification method Material chemistry 3.1.1 D3 Work Envelope 3.2.1 R1 D2 R2 Powder Feed Rate 3.2.2 R1 D2 R2 Layer Thickness 3.2.3 R1 D2 R2 Variable Spot Size 3.2.4 R1 D2 R2 Minimum Wall Thickness 3.2.5 R1 D2 R2

Part Geometry Features 3.2.6 R1 or DS P

Control 3.3.1 R1 R2

Number of Axes 3.3.2 R1 R2

Laser System 3.3.3 R1 R2

Deposition Head/Nozzle 3.3.4 R1 R2

Powder Feeder(s) 3.3.5 R1 R2

Process Monitoring 3.3.6 R1 R2 Equipment Size 3.3.7 D2 R1 R2 Equipment Weight 3.3.8 D2 R1 R2 Laser Enclosure 3.3.9.1 D2 R1 R2 Viewing Window 3.3.9.2 D2 R1 R2 Atmosphere Control 3.3.9.3 D2 R1 R2 Antechamber 3.3.9.4 D2 R1 R2 Parts Handling 3.3.9.5 D2 R1 R2 Operational Environment 3.3.10 D2 D3 Electrical Power Requirements 3.3.11 D2 R1 Cooling Water 3.3.12 D2 R1 R2 Compressed Air 3.3.13 D2 R1 R2

Nitrogen 3.3.14 D2 R1 R2

Argon 3.3.15 D2 R1 R2

Supporting Software 3.4.1 R1 R2 R3 R4 R5

Computer 3.4.2 R1 or D2 R2 or D3

Supporting Documentation 3.5 D2

Operation requirements 4.0 D2 R1 R2

Safety Requirements 5.0 R1 or D2 R2, V or P R3 R4 R5

6.4 Verification Methods

Verification of the metallic AM Powder Blown System requirements will be accomplished by 1) reference 2) documentation 3) demonstration samples, and 4) Video, or a combination thereof as defined below.

6.4.1 Reference

A Point of contact, with appropriate contact information, of someone operating (or in charge of the operation of) the AM Powder Blown System that can be used as a reference to validate a requirement

6.4.2 Documentation

Documentation refers to polished documents which provide verification of a vendors claims.

6.4.3 Demonstration Samples

Demonstration samples are defined as samples provided by the vendor which verify the claims that the requirement has been met. The vendor must supply in writing that these sample have been made by the AM Powder Blown System being proposed.

6.4.4 Video / Pictures

Video / Pictures is defined as a digital recording or picture which verify the requirements. The vendor must supply in writing that these are authentic.

Table 6.2-1 Verification Methods

METHOD DEFINITION

R1 Government Reference A point of contact at a US Government agency who can verify that the requirement has been met.

R2 Defense Industry A point of contact at a Major Defense Contractor who can verify that the requirement has been met.

For the purposes of this document, a major defense contractor is one who has done $100 Million of work for the US Department of Defense.

R3 US academic A point of contact at a US accredited University who can verify that the requirement has been met.

R4 US industry A point of contact at a US business who can verify that the requirement has been met. The Point of contact must be a US citizen.

R5 Foreign Industry A point of contact at any business who can verify that the requirement has been met.

D1 3rd Party Certification A Certification provided from an independent organization documenting the requirement has been met.

D2 Vendor Manuals A manual currently supplied with the equipment which will document that the requirement has been met

D3 Vendor Brochure A published Brochure from the Vendor which will document that the requirement has been met.

DS Demonstration Samples Sample provided at the vendors expense with the proposal which can show that the AM Powder Blown System can meet the requirement.

V Video A digital video which can show the requirement has been met. Any video used to validate a time requirement must be of the entire process and of substantial detail such that the required time can be measured.

P Picture A digital picture in Jpeg format of the AM Powder Blown System or of an item the AM Powder Blown System has made which can show the specified requirement has been met.

Appendix A

Building Layout

3.5 Supporting Documentation