Additive Manufacturing for the Aerospace Industry

Dr. Froes has been involved in the Titanium field with an emphasis on Powder Metallurgy (P/M) for more than 40 years. He was employed by a primary Titanium producer—Crucible Steel Company—where he was leader of the Titanium group. He was the program manager on a multi-million dollar US Air Force (USAF) contract on Titanium P/M. He then spent time at the USAF Materials Lab where he was supervisor of the Light Metals group (which included Titanium). This was followed by 17 years at the University of Idaho where he was a Director and Department Head of the Materials Science and Engineering Department. He has over 800 publications, in excess of 60 patents, and has edited almost 30 books—the majority on various aspects of Titanium again with an emphasis on P/M. He gave the key-note presentation at the first TDA (ITA) Conference. In recent years he has co-sponsored four TMS Symposia on Cost Effective Titanium featuring numerous papers on P/M. He is a Fellow of ASM, is a member of the Russian Academy of Science, and was awarded the Service to Powder Metallurgy by the Metal Powder Association. Rod Boyer was employed at The Boeing Company from 1965 through 2011, and is now aconsultant. He has specialized in titanium for over 40 years. Mr. Boyer, a Fellow of ASM andBoeing Technical Fellow, received the Russ Ogden Award from ASTM for outstandingachievements in the areas of reactive and refractory metals and the ASM William Hunt Wiseman Award for outstanding achievements in the development and implementation of titanium alloys and processes for aircraft use. During his tenure at Boeing, Mr. Boyer was a titanium specialist involved in basic research, development and applications of titanium alloys for airframes. He has done research on all product forms used on aircraft, and studied almost all of the processes involved in the fabrication of titanium components, from mill processing to machining and chemical processing. He had a strong focus on powder metallurgy during his last three years at Boeing. He has co-edited 6 books, the most notable being the Titanium Alloys Materials Properties Handbook published by ASM. He has over 250 technical presentations and publications, including 35 invited presentations at the regional, national and international levels, with 7 plenary/keynote presentations at the national level and 11 at international symposia.

• 1. Introduction to Aerospace Materials Requirements and the Role of Additive Manufacturing2. Review of Additive Manufacturing Technologies and Applications in the Aerospace Industry3. Qualification of Metal Additive Manufacturing for Aerospace Applications4. High Quality Additive Manufactured Parts via Wire Feed/Plasma Arc Technology for Aerospace5. Design for Metal Additive Manufacturing for Aerospace Applications6. Structure formation in A.M. processes of Titanium and Ni-base alloys7. Measurement of Powder Characteristics and Quality for Additive Manufacturing in Aerospace Alloys8. The influence of processing and heat treatment parameters on selective laser melted aluminium alloy A3579. Novel process monitoring techniques and materials in Additive Manufacturing10. Fusion and/or Solid State Additive Manufacturing for Aerospace Applications11. Wire Feed Technology for Additive Manufacturing of Ti-6Al-4V 12. Profile Electron Beam 3-D Printing13. Additive Manufacturing of Titanium Aluminides14. Aerospace applications of the SLM process of functional and functional graded metal-matrix composites based on titanium or Ni-Cr15. Surface Roughness and Fatigue Properties of Selective Laser Melted Ti-6Al-4V Alloy as a Function of Processing Conditions16. AM Al alloys 17. Additive Manufacturing for the Aerospace Industry18. Surface Texture Characterization and Optimization for AM Produced Components forAerospace Applications 19. Applying ICME and Computational Tools to Predict the Performance of AM Aerospace Components20. NDE of AM Metal Parts, in-situ and Post Deposition 21. Combining Additive Manufacturing with Conventional Casting and Reduced Density Materials to Greatly Reduce the Weight of Airplane Components such as Passenger Seat Frames22. Stabilization of thickness in direct deposition of a layer by production for aerospace applications

"This collection is a useful tool for understanding the future of aerospace production techniques and does highlight accurately the challenges airframers and propulsion engineers will face. However, it is important to note that this area is moving so rapidly that I would expect a similar compilation to have a very different feel within two years. A good overview and reference for the curious reader but perhaps of limited value longer term in a rapidly maturing field." --The Aeronautical Journal