Tech Pub S9074-A4-GIB-010_AM-WIRE DED Rev 1.pdf

S9074-A4-GIB-010/AM-WIRE DED

REVISION 1

NAVSEA TECHNICAL PUBLICATION

REQUIREMENTS FOR METAL WIRE-FED DIRECTED

ENERGY DEPOSITION ADDITIVE MANUFACTURING

Supersedure Notice: This revision supersedes S9074-A4-GIB-010/AM-WIRE DED dated 27 May 2021.

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE: DISTRIBUTION IS UNLIMITED.

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

08 JULY 2024

S9074-A4-GIB-010/AM-WIRE DED, Rev 1

RECORD OF REVISIONS-1/(RECORD OF REVISIONS-2 Blank)

RECORD OF REVISIONS

REVISION

NO. DATE TITLE OR BRIEF DESCRIPTION/PREPARING ACTIVITY

0 27 MAY 2021 Initial issue.

1 08 JULY 2024 This revision streamlines the qualification process for metal Directed

Energy Deposition (DED) Additive Manufacturing procedures and components using wire feedstock and added allowances for additional

DED technologies. The requirement for approval of the DED

Procedure prior to execution of procedure qualification builds has been removed. The requirements for the DED Procedure and the procedure qualification requirements have been changed to better match commercial best practices. The requirement to perform nondestructive testing in all cases have been streamlined and clarified. Destructive testing requirements have been streamlined for procedure qualification and part verification. Electron beam and laser DED requirements have been added. Other clarifications to requirements have been made throughout the document.

FOREWORD-1/(FOREWORD-2 Blank)

FOREWORD

This document covers general requirements, provisions for quality assurance and Process Control Plans, test procedures, and instructions for preparation for delivery of directed energy deposition-produced parts.

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TABLE OF CONTENTS

Chapter/Paragraph Page

Chapter 1 Scope and Applicability ............................................................................................................ 1-1

1-1 Scope. ........................................................................................................................................... 1-1

1-2 Non-Applicability. ....................................................................................................................... 1-1

1-2.1 Naval Nuclear Propulsion. .................................................................................................. 1-1

1-2.2 Strategic Systems Programs. .............................................................................................. 1-1

1-2.3 Non-Critical Applications. .................................................................................................. 1-1

1-3 Requirements Subject to NAVSEA Approval. ............................................................................ 1-1

1-4 Referenced Documents. ............................................................................................................... 1-2

1-4.1 Government Documents. .................................................................................................... 1-2

1-4.1.1 Defense Standardization Program Documents. ......................................................... 1-2

1-1.4.2 Other Government Publications. ............................................................................... 1-4

1-4.2 Non-Government Documents. ............................................................................................ 1-5

1-4.3 Cancelled Specifications. .................................................................................................. 1-13

1-4.4 Order of Precedence. ........................................................................................................ 1-17

1-5 Definitions. ................................................................................................................................. 1-17

1-5.1 Terms Related to Additive Manufacturing (AM). ............................................................ 1-17

1-5.1.1 General. ................................................................................................................... 1-17

1-5.1.2 Acceptable. .............................................................................................................. 1-17

1-5.1.3 Active Cooling. ....................................................................................................... 1-17

1-5.1.4 Activity.................................................................................................................... 1-17

1-5.1.5 Additive Manufacturing. ......................................................................................... 1-17

1-5.1.6 AM Authorized Representative. .............................................................................. 1-17

1-5.1.7 Approval (Approved). ............................................................................................. 1-17

1-5.1.8 Build. ....................................................................................................................... 1-17

1-5.1.9 Build Platform. ........................................................................................................ 1-17

1-5.1.10 Digital File. ........................................................................................................... 1-17

1-5.1.11 Directed Energy Deposition (DED). ..................................................................... 1-18

1-5.1.11.1 Arc-Wire DED. ............................................................................................ 1-18

1-5.1.11.2 Electron Beam Wire Directed Energy Deposition (DED). .......................... 1-18

1-5.1.11.3 Laser Wire DED. ......................................................................................... 1-18

1-5.1.12 Essential Elements. ............................................................................................... 1-18

1-5.1.13 Fabrication Document. .......................................................................................... 1-18

1-5.1.14 Family of Parts. ..................................................................................................... 1-18

1-5.1.15 Flat Position. ......................................................................................................... 1-18

1-5.1.16 Heat Treatment. ..................................................................................................... 1-18

1-5.1.17 Integrated Build. .................................................................................................... 1-18

1-5.1.18 Interpass. ............................................................................................................... 1-18 ii

Chapter/Paragraph Page

1-5.1.19 Interlayer. .............................................................................................................. 1-18

1-5.1.20 Layer Height. ........................................................................................................ 1-18

1-5.1.21 Machine. ................................................................................................................ 1-18

1-5.1.22 Non-Integrated Build. ........................................................................................... 1-18

1-5.1.23 Operator. ............................................................................................................... 1-18

1-5.1.24 Oscillation. ............................................................................................................ 1-18

1-5.1.25 Part. ....................................................................................................................... 1-19

1-5.1.26 Part Verification Build. ......................................................................................... 1-19

1-5.1.27 Position.................................................................................................................. 1-19

1-5.1.28 Power Source. ....................................................................................................... 1-19

1-5.1.29 Procedure. ............................................................................................................. 1-19

1-5.1.30 Procedure Qualification. ....................................................................................... 1-19

1-5.1.31 Procedure Qualification Build............................................................................... 1-19

1-5.1.32 Review for Adequacy. ........................................................................................... 1-19

1-5.1.33 Special DED Applications/Parts. .......................................................................... 1-19

1-5.1.34 System. .................................................................................................................. 1-19

1-5.1.35 TP 248 Authorized Representative. ...................................................................... 1-19

1-5.1.36 Waiver. .................................................................................................................. 1-19

1-5.1.37 Witness Coupon. ................................................................................................... 1-19

1-6 Classification. ............................................................................................................................. 1-19

1-6.1 Included Classification. .................................................................................................... 1-19

1-6.2 Other Classifications. ........................................................................................................ 1-21

Chapter 2 Qualification Requirements and Test Reports ........................................................................... 2-1

2-1 Scope. ........................................................................................................................................... 2-1

2-2 General Requirements and Test Reports. ..................................................................................... 2-1

2-2.1 Responsibility. .................................................................................................................... 2-1

2-2.1.1 Qualification Builds. ................................................................................................. 2-1

2-2.2 Certification of Qualification Testing. ................................................................................ 2-1

2-2.2.1 Approval of Other Procedure Qualifications. ........................................................... 2-1

2-2.3 Submittal of Procedures, Test Plans, and Test Reports. ..................................................... 2-1

2-2.3.1 Review for Adequacy. ............................................................................................... 2-2

2-2.3.2 Procedure Approval. ................................................................................................. 2-2

2-2.3.3 Part Acceptance. ........................................................................................................ 2-2

2-2.3.4 Approval by Audit. ................................................................................................... 2-2

2-2.3.5 AM Authorized Representative Advanced Notification. .......................................... 2-2

2-2.4 Vendor Procedure Qualification. ........................................................................................ 2-2

2-2.5 Waiver of Qualification. ..................................................................................................... 2-2

2-2.6 Approval of Critical Applications. ..................................................................................... 2-3

2-2.7 Approval of Procedure Qualification for Special DED Parts and Applications. ................ 2-3 iii

Chapter/Paragraph Page

2-2.7.1 DED Repair. .............................................................................................................. 2-3

2-2.7.2 Alternative Heat Sources........................................................................................... 2-3

2-2.8 Qualification Level. ............................................................................................................ 2-3

2-2.8.1 Level 1....................................................................................................................... 2-3

2-2.8.2 Level 2....................................................................................................................... 2-3

2-2.8.3 Part Level. ................................................................................................................. 2-3

2-2.9 Repair of Procedure Qualification Builds and Part Verification Builds. ............................ 2-3

2-2.9.1 Insufficient Procedure Qualification and Part Verification. ...................................... 2-3

2-2.10 Transfer of Procedure Qualification for DED Material. ................................................... 2-3

2-2.10.1 Transfer of Qualified Procedures Between Sites of an Activity. ............................ 2-4

2-2.11 Transfer of Operator Qualification. .................................................................................. 2-4

Chapter 3 DED Procedure Qualification ................................................................................................... 3-1

3-1 Scope. ........................................................................................................................................... 3-1

3-2 DED Procedure. ........................................................................................................................... 3-1

3-2.1 Essential Elements of the DED Procedure. ........................................................................ 3-1

3-2.2 Build Platform and Feedstock Material. ............................................................................. 3-5

3-2.3 Material Acceptance Criteria. ............................................................................................. 3-5

3-2.3.1 Established DED Acceptance Criteria. ..................................................................... 3-5

3-2.3.2 Input Material Derived Acceptance Criteria. ............................................................ 3-5

3-2.3.3 Other Existing Acceptance Criteria. ....................................................................... 3-29

3-2.3.4 New Acceptance Criteria. ....................................................................................... 3-29

3-2.4 Preheat and Interpass Temperatures. ................................................................................ 3-30

3-2.4.1 Methods of Preheating and Interpass Temperature Control. ................................... 3-30

3-2.5 Heat Treatment. ................................................................................................................ 3-34

3-2.5.1 Minimum Requirement. .......................................................................................... 3-34

3-2.6 Titanium Build Control Plan. ........................................................................................... 3-34

3-2.7 Thermal Monitoring Equipment. ...................................................................................... 3-34

3-2.7.1 Thermal Monitoring Equipment Calibration........................................................... 3-35

3-2.8 Active Cooling. ................................................................................................................. 3-35

3-2.9 Oscillation. ........................................................................................................................ 3-35

3-2.10 Procedures With As-Built Surfaces. ............................................................................... 3-35

3-2.11 Review for Adequacy. .................................................................................................... 3-35

3-3 DED Procedure Qualification Test Plan. ................................................................................... 3-35

3-3.1 Scope. ............................................................................................................................... 3-35

3-3.2 Procedure Qualification Builds......................................................................................... 3-35

3-3.2.1 Procedure Qualification Build Design. ................................................................... 3-35

3-3.2.1.1 Procedure Qualification Build Quantity. ....................................................... 3-35

3-3.2.1.2 Procedure Qualification Thickness Limits. ................................................... 3-35

3-3.2.2 Procedure Qualification Build Platform and Feedstock Material. .......................... 3-35 iv

Chapter/Paragraph Page

3-3.2.2.1 Build Platforms for Integrated Build Procedure Qualification Builds. ......... 3-35

3-3.2.3 Essential Element Parameter Ranges. ..................................................................... 3-36

3-3.2.3.1 Interpass Temperature for Procedure Qualification Builds. .......................... 3-36

3-3.2.3.2 Fixed Heat Input Procedures. ........................................................................ 3-36

3-3.2.3.3 Requirements for Maximum and Minimum Heat Input. ............................... 3-36

3-3.3 Build Layout. .................................................................................................................... 3-36

3-3.3.1 Post Processing. ...................................................................................................... 3-36

3-3.3.1.1 Surface Finish. ............................................................................................... 3-36

3-3.3.1.2 Heat Treatment. ............................................................................................. 3-36

3-3.3.1.3 Other Post-Processing Procedures. ................................................................ 3-36

3-3.4 Start and Stop Positions. ................................................................................................... 3-39

3-3.5 NDT. ................................................................................................................................. 3-39

3-3.6 Visual Testing. .................................................................................................................. 3-39

3-3.7 Surface Inspection. ........................................................................................................... 3-39

3-3.8 Volumetric Inspection. ..................................................................................................... 3-39

3-3.8.1 UT Calibration. ....................................................................................................... 3-39

3-3.9 NDT for Integrated Build Platforms. ................................................................................ 3-39

3-3.10 Destructive Testing. ........................................................................................................ 3-39

3-4 Procedure Qualification Test Report. ......................................................................................... 3-39

3-5 Changes Requiring Level 1 Requalification of Procedure. ........................................................ 3-40

3-5.1 Machine. ........................................................................................................................... 3-40

3-5.2 Build Platform. ................................................................................................................. 3-40

3-5.3 Feedstock Material. .......................................................................................................... 3-40

3-5.4 Deposition Procedure. ...................................................................................................... 3-40

3-5.5 Process. ............................................................................................................................. 3-40

3-5.6 Power Source Parameters. ................................................................................................ 3-41

3-5.7 Shielding Gas (Torch, Purge Gas). ................................................................................... 3-41

3-5.8 Preheat and Interpass Temperatures. ................................................................................ 3-42

3-5.9 In-Process Machining and Grinding. ................................................................................ 3-42

3-5.10 Post-Build Processing. .................................................................................................... 3-42

3-5.11 Active Cooling. ............................................................................................................... 3-42

3-6 Changes Requiring Level 2 Requalification of Procedure. ........................................................ 3-42

3-6.1 Machine. ........................................................................................................................... 3-42

3-6.2 Deposition Procedure. ...................................................................................................... 3-42

3-6.3 Build Platform. ................................................................................................................. 3-43

3-6.4 Process. ............................................................................................................................. 3-43

3-6.5 Power Source Parameters. ................................................................................................ 3-43

3-6.6 Wire Feed. ........................................................................................................................ 3-43

3-6.7 Shielding Gas (Torch, Purge Gas). ................................................................................... 3-43 v

Chapter/Paragraph Page

3-6.8 Preheat and Interpass Temperature. .................................................................................. 3-43

3-6.9 In-Process Machining and Grinding. ................................................................................ 3-43

3-6.10 Post-Build Processing. .................................................................................................... 3-43

Chapter 4 Part Verification Procedure ....................................................................................................... 4-1

4-1 Scope. ........................................................................................................................................... 4-1

4-2 Part Manufacturing Plan. ............................................................................................................. 4-1

4-2.1 Essential Elements. ............................................................................................................. 4-1

4-2.2 Material Acceptance Criteria. ............................................................................................. 4-1

4-2.2.1 NDT Acceptance Criteria. ......................................................................................... 4-1

4-2.3 Build Layouts. .................................................................................................................... 4-1

4-2.4 Part Manufacturing Build Sequence. .................................................................................. 4-1

4-2.4.1 Family of Part Changes Not Requiring Part Requalification. ................................... 4-1

4-2.4.2 Witness Coupons. ...................................................................................................... 4-2

4-3 Part Verification Test Plan. .......................................................................................................... 4-2

4-3.1 Part Verification Builds. ..................................................................................................... 4-2

4-3.1.1 Start and Stop Positions. ........................................................................................... 4-2

4-3.2 Nondestructive Testing. ...................................................................................................... 4-2

4-3.2.1 Use of Sensors. .......................................................................................................... 4-2

4-3.3 Destructive Testing. ............................................................................................................ 4-2

4-3.3.1 Metallographic Specimens. ....................................................................................... 4-2

4-3.3.2 Application-Specific Requirements. ......................................................................... 4-2

4-4 Part Verification Test Report. ...................................................................................................... 4-3

4-4.1 Work Instructions. .............................................................................................................. 4-3

4-5 Part Requalification. ..................................................................................................................... 4-3

4-5.1 Qualification Level 1 Changes. .......................................................................................... 4-3

4-5.2 Digital Files. ....................................................................................................................... 4-3

4-5.3 Build Platform. ................................................................................................................... 4-3

4-5.4 Feedstock Material. ............................................................................................................ 4-3

4-5.5 In-Process Machining. ........................................................................................................ 4-3

4-5.6 Active Cooling. ................................................................................................................... 4-3

Chapter 5 Production Conformance Evaluation Plan ................................................................................ 5-1

5-1 Scope. ........................................................................................................................................... 5-1

5-2 General Requirements. ................................................................................................................. 5-1

5-2.1 Production Conformance Testing. ...................................................................................... 5-1

5-2.2 Build Layout Figures. ......................................................................................................... 5-1

5-2.3 Use of Part Verification Test Plan as Production Conformance evaluation plan. .............. 5-1

5-3 Witness Coupons. ......................................................................................................................... 5-2

5-4 NDT and Repairs. ........................................................................................................................ 5-2

5-4.1 Non-Pressurized Machinery. .............................................................................................. 5-2 vi

Chapter/Paragraph Page

5-4.2 Pressurized Machinery and Pressure Vessels. .................................................................... 5-2

5-4.3 Piping. ................................................................................................................................. 5-2

5-4.4 Other Builds. ....................................................................................................................... 5-2

5-4.5 Acceptance Criteria. ........................................................................................................... 5-2

5-4.6 Use of Sensors. ................................................................................................................... 5-2

5-4.7 Repair of Production Builds. ............................................................................................ 5-12

5-4.7.1 Post-Build Repair. ................................................................................................... 5-12

5-4.7.1.1 Post-Build Repair NDT Records. .................................................................. 5-12

5-5 Destructive Testing. ................................................................................................................... 5-12

5-6 Production Conformance Test Report. ....................................................................................... 5-12

5-6.1 Certificate of Production Conformance. ........................................................................... 5-12

5-7 Responsibility for Production Conformance. ............................................................................. 5-12

Chapter 6 DED Operator Qualification ..................................................................................................... 6-1

6-1 Scope. ........................................................................................................................................... 6-1

6-2 General Requirements. ................................................................................................................. 6-1

6-2.1 Responsibility. .................................................................................................................... 6-1

6-2.2 Prerequisite. ........................................................................................................................ 6-1

6-2.3 Methods of Establishing Qualification. .............................................................................. 6-1

6-2.3.1 DED Operator Training in Workmanship. ................................................................ 6-1

6-2.3.2 System Training and Testing Requirements. ............................................................ 6-1

6-2.4 Alternative Qualification Methods. .................................................................................... 6-2

6-2.5 Requirements for Special DED Builds. .............................................................................. 6-2

6-2.5.1 Separation of Operator Roles. ................................................................................... 6-2

6-2.5.2 Operator Roles Not Requiring Operator Qualification Testing. ............................... 6-2

6-2.6 Repair to Operator Qualification Test Builds. .................................................................... 6-2

6-2.7 Retests. ................................................................................................................................ 6-2

6-2.8 Maintenance of Operator Qualification. ............................................................................. 6-2

6-2.8.1 Renewal of Qualification. ......................................................................................... 6-3

6-2.8.1.1 Renewal of Qualification for Titanium............................................................ 6-6

6-2.9 Vision Test Requirements. ................................................................................................. 6-6

6-2.9.1 Titanium. ................................................................................................................... 6-6

6-2.10 Loss of Operator Qualification. ........................................................................................ 6-6

6-3 Operator Qualification Test Requirements. ................................................................................. 6-6

6-3.1 Operator Qualification Test Builds. .................................................................................... 6-6

6-3.2 Requirements for Titanium. ................................................................................................ 6-6

6.4 Test and Evaluation of Qualification Test Builds. ....................................................................... 6-6

6-4.1 NDT. ................................................................................................................................... 6-6

6-4.2 Destructive Tests. ............................................................................................................... 6-6

6-5 Data Accumulation and Records. ................................................................................................. 6-7 vii

Chapter/Paragraph Page

6-5.1 Operator Qualification Test Records. ................................................................................. 6-7

6-5.2 Disposable Data. ................................................................................................................. 6-7

6-5.3 Qualification Currency Record. .......................................................................................... 6-7

6-5.4 Vision Test Records. ........................................................................................................... 6-7

6-6 Changes Requiring Requalification of DED Operator. ................................................................ 6-7

6-6.1 Filler Material. .................................................................................................................... 6-7

6-6.2 Process. ............................................................................................................................... 6-7

6-6.3 Shielding Gas. ..................................................................................................................... 6-8

6-6.4 Fabrication Document Requirements. ................................................................................ 6-8

Chapter 7 Quality Assurance, Process Control, and Training Plans .......................................................... 7-1

7-1 Scope. ........................................................................................................................................... 7-1

7-2 Quality Assurance System. .......................................................................................................... 7-1

7-2.1 Material Control. ................................................................................................................ 7-1

7-2.1.1 Identification System. ............................................................................................... 7-1

7-2.1.2 Visual Verification of Materials Prior to Use. .......................................................... 7-1

7-2.2 Records. .............................................................................................................................. 7-1

7-2.2.1 Record Form. ............................................................................................................ 7-1

7-2.2.2 Maintenance of Records. ........................................................................................... 7-2

7-2.3 Nonconformance. ............................................................................................................... 7-2

7-3 Process Control Plan. ................................................................................................................... 7-2

7-3.1 Change Control Plan. .......................................................................................................... 7-2

7-3.2 Personnel Training Plan. ..................................................................................................... 7-2

7-3.3 Maintenance Control Plan. ................................................................................................. 7-3

7-3.4 Digital File Handling Plan. ................................................................................................. 7-3

7-3.4.1 Software Configuration Management Plan. .............................................................. 7-3

7-3.5 Feedstock Material Plan. .................................................................................................... 7-3

7-3.6 Build Procedure. ................................................................................................................. 7-4

7-3.7 Post-Processing Procedure.................................................................................................. 7-4

7-3.8 In-Process Monitoring Plan. ............................................................................................... 7-4

7-3.9 Data Collection System. ..................................................................................................... 7-4

Chapter 8 Evaluation .................................................................................................................................. 8-1

8-1 Scope. ........................................................................................................................................... 8-1

8-2 General Evaluation Requirements. ............................................................................................... 8-1

8-2.1 Rejection and Retests. ......................................................................................................... 8-1

8-2.2 Reheat Treatment. ............................................................................................................... 8-1

8-2.3 Defective Specimen/Replacement of Test Specimens. ....................................................... 8-1

8-3 NDT. ............................................................................................................................................ 8-2

8-3.1 Visual Inspection. ............................................................................................................... 8-2

8-3.1.1 Titanium and Titanium Alloys. ................................................................................. 8-2 viii

Chapter/Paragraph Page

8-3.2 Dimensional Examination. ................................................................................................. 8-2

8-3.3 MT and PT. ......................................................................................................................... 8-2

8-3.3.1 MT and PT Suitability. .............................................................................................. 8-2

8-3.4 RT Inspection. .................................................................................................................... 8-2

8-3.4.1 Radiographic Shooting Sketch. .................................................................................. 8-3

8-3.5 UT Inspection. .................................................................................................................... 8-3

8-3.5.1 UT Scan Plan. ............................................................................................................ 8-3

8-3.5.2 Calibration Block Weld Process Equivalency. ......................................................... 8-3

8-3.6 Integrated Build Platform. .................................................................................................. 8-3

8-3.6.1 UT of Integrated Build Platform. .............................................................................. 8-4

8-3.6.1.1 UT Calibration for Integrated Build Platform. ................................................ 8-4

8-3.6.1.2 UT Acceptance Criteria for Integrated Build Platform. .................................. 8-5

8-3.7 Alternate NDT Methods. .................................................................................................... 8-5

8-3.8 Weld Acceptance Criteria Areas Versus DED Build Areas for RT, MT, and PT. ............. 8-5

8-3.9 Start and Stop Location. ..................................................................................................... 8-6

8-4 Destructive Testing. ..................................................................................................................... 8-6

8-4.1 Tension Tests. ..................................................................................................................... 8-6

8-4.2 Guided Bend Test. .............................................................................................................. 8-6

8-4.2.1 Criteria for Acceptance. ............................................................................................ 8-6

8-4.3 Charpy V-Notch (CVN). .................................................................................................... 8-6

8-4.3.1 HAZ Photomacrographs............................................................................................ 8-6

8-4.4 Metallographic Specimens.................................................................................................. 8-7

8-4.4.1 Macroetch Specimens. .............................................................................................. 8-7

8-4.4.2 Microstructural Analysis Specimens. ........................................................................ 8-7

8-4.4.3 Metallographic Features. ........................................................................................... 8-7

8-4.5 Hardness Test. .................................................................................................................... 8-8

8-4.6 Chemistry. .......................................................................................................................... 8-8

8-4.7 Special Tests. ...................................................................................................................... 8-8

Chapter 9 Acquisition ................................................................................................................................ 9-1

9-1 Scope. ........................................................................................................................................... 9-1

9-2 Acquisition Requirements. ........................................................................................................... 9-1

9.3 Part Verification Build. ................................................................................................................ 9-1

9-3.1 New Vendors. ..................................................................................................................... 9-1

9-4 Preparation for Packaging and Packing. ...................................................................................... 9-1

9-4.1 Packaging, Packing, and Marking for Shipment. ............................................................... 9-1

9-4.2 Packaging by Department of Defense (DoD) Personnel. ................................................... 9-1

Appendix A Abbreviations and Acronyms ............................................................................................... A-1

A-1 Abbreviations and Acronyms. .................................................................................................... A-1 ix/(x Blank)

LIST OF TABLES

Table Title Page

Table 3-1. Essential Elements of DED ..................................................................................................... 3-1

Table 3-2. Build Platform Materials ......................................................................................................... 3-6

Table 3-3. Feedstock Materials ............................................................................................................... 3-26

Table 3-4. Preheat and Interpass Temperature Limits ............................................................................ 3-30

Table 3-5. Destructive Testing Requirements for Maximum Thickness Blocks .................................... 3-37

Table 3-6. Destructive Testing Requirements for Minimum Thickness Blocks ..................................... 3-38

Table 3-7. Sample Procedure Qualification Report for Directed Energy Deposition ............................. 3-44

Table 3-8. Sample Form: Tensile Test Results ...................................................................................... 3-46

Table 3-9. Sample Form: Charpy V-Notch Test Results ....................................................................... 3-46

Table 3-10. Sample Hardness Test Results Form ................................................................................... 3-46

Table 5-1. Conformance Testing .............................................................................................................. 5-1

Table 5-2. Non-Pressure Containing Builds in Machinery ....................................................................... 5-3

Table 5-3. Inspection for Pressurized Machinery and Pressure Vessels ................................................... 5-5

Table 5-4. Class P Piping Component Inspection Requirements ............................................................. 5-8

Table 6-1. Sample DED Operator Qualification Record .......................................................................... 6-4

Table 6-2. Test Requirements for DED Operator Qualification ............................................................... 6-6

LIST OF ILLUSTRATIONS

Figure Title Page

Figure 8-1. Maximum Acceptable Ultrasonic Indication Length for Deposition-to-Build Platform Fusion

Zone ................................................................................................................................................... 8-5

1-1

CHAPTER 1

SCOPE AND APPLICABILITY

1-1 SCOPE.

This document provides the minimum qualification requirements, part verification requirements, and performance requirements for fabricating metal components using directed energy deposition (DED) additive manufacturing (AM) with wire feedstock. This document also covers the general requirements, provisions for quality assurance and Process Control Plan, test procedures, and instructions in preparation for delivery of DED-produced materials. Procedure qualification, part verification, and operator qualification requirements, as well as completion of all assessments and requirements for NAVSEA’s use of AM shall be met prior to any production fabrication, as specified in NAVSEA Letter 4870 Ser

05T/2018-024 or as superseded. The requirements in this document are devised to demonstrate that sound

DED parts can be produced. This document does not purport to address all the safety concerns associated, if any, with the use of DED. It is the responsibility of the user of this document to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

1-2 NON-APPLICABILITY.

1-2.1 NAVAL NUCLEAR PROPULSION. This document does not apply to naval nuclear propulsion plant systems, equipment, and facilities under the cognizance of the Deputy Commander, Nuclear

Propulsion Directorate (SEA 08). As outlined in EO 12344, the SEA 08 Deputy Commander has responsibilities and authorities over all facilities and activities that comprise the Naval Nuclear Propulsion

Program, which is a joint Department of Energy and Navy organization. These responsibilities and authorities include all technical and logistical matters related to naval nuclear propulsion. Accordingly, nothing in this document supersedes or changes those authorities, and SEA 08 shall be consulted concerning all matters related to naval nuclear propulsion.

1-2.2 STRATEGIC SYSTEMS PROGRAMS. This document does not apply to Strategic Weapons

Systems, Attack Weapons Systems, and associated spares and repair parts under the cognizance of Strategic

Systems Programs.

1-2.3 NON-CRITICAL APPLICATIONS. This document does not apply to applications covered by

NAVSEA Letter 9070 Ser 05Z/191 or to applications with service condition level severities of level 7 and

N/A, in accordance with NAVSEA’s requirements on the use of AM.

1-3 REQUIREMENTS SUBJECT TO NAVSEA APPROVAL.

Any requirements contained in this document specifically requiring NAVSEA approval shall be forwarded to Naval Sea Systems Command, SEA 05T1, 1333 Isaac Hull Ave SE Stop 5142, Washington Navy Yard, DC 20376-5142 via the AM Authorized Representative.