TY - BOOK
T1 - Development and Demonstration of Large-Scale Metal Additive Manufacturing for Military Vehicle Applications (Final Report)
AU - Love, Lonnie J.
AU - Nycz, Andrzej
AU - Noakes, Mark
AU - Post, Brian
AU - Roschli, Alex
AU - Babu, Sudarsanam
PY - 2016
Y1 - 2016
N2 - Additive Manufacturing (AM) is a process by which complex parts can be manufactured directly from a basic feedstock without the need for tooling. From a defense perspective, this will enable direct manufacture of parts for legacy equipment. However, current AM technologies are limited to small part sizes (approximately 1 cubic foot), slow production rates (approximately 1 cubic inch per hour) and expensive feedstocks (approximately $100/lb). The objective of this project was to explore the impact large-scale, high production rate additive manufacturing can have on military applications. First, the program explored the use of existing composite large-scale (Big Area Additive Manufacturing – BAAM) systems for both tooling and direct part replacement with the use of the Army’s Low Velocity Airdrop Delivery (LVAD) system and Willy’s Jeep. We report on the cost and time required for the development of both tooling and parts. Second, the program focused on expanding the BAAM technology to directly manufacture aluminum and steel components. A robotic welding system was developed, test articles manufactured and with a final deliverable of a steel bumper manufactured and installed on the Jeep. This report covers the results of the program and describes follow-on efforts to commercialize the technology.
AB - Additive Manufacturing (AM) is a process by which complex parts can be manufactured directly from a basic feedstock without the need for tooling. From a defense perspective, this will enable direct manufacture of parts for legacy equipment. However, current AM technologies are limited to small part sizes (approximately 1 cubic foot), slow production rates (approximately 1 cubic inch per hour) and expensive feedstocks (approximately $100/lb). The objective of this project was to explore the impact large-scale, high production rate additive manufacturing can have on military applications. First, the program explored the use of existing composite large-scale (Big Area Additive Manufacturing – BAAM) systems for both tooling and direct part replacement with the use of the Army’s Low Velocity Airdrop Delivery (LVAD) system and Willy’s Jeep. We report on the cost and time required for the development of both tooling and parts. Second, the program focused on expanding the BAAM technology to directly manufacture aluminum and steel components. A robotic welding system was developed, test articles manufactured and with a final deliverable of a steel bumper manufactured and installed on the Jeep. This report covers the results of the program and describes follow-on efforts to commercialize the technology.
KW - 36 MATERIALS SCIENCE
KW - 45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEFENSE
U2 - 10.2172/1569396
DO - 10.2172/1569396
M3 - Commissioned report
BT - Development and Demonstration of Large-Scale Metal Additive Manufacturing for Military Vehicle Applications (Final Report)
CY - United States
ER -