Development of Laser Additive Manufacturing Repair (LAM-R) Transition Procedures Supporting Maintenance & Sustainment

NCMS Project #: 140870

Problem: Unfortunately, in its current state, additive manufacturing (AM) is not sufficiently understood nor characterized such that conventional design practices and process qualification methodologies can be used; therefore, no qualified suppliers exist. This lack of maturity in terms of design, qualification, and procurement procedures is the overarching barrier to implementing AM with the general public.

Benefit: Benefits of LAM-R technology makes it possible to repair parts that were previously unrepairable. The knowledge learned from this project will be transferred in to the public on LAM-R repair.

Solution/Approach: Process qualification is a major concern for transitioning any new process into the aircraft design and manufacturing community. Hence, specifications, design databases, and qualification protocols must be made available for LAM-R and similar new technologies before they can gain wide acceptance in the aircraft industry. One important strategic implementation point is to perform actual component testing of the new AM processes under design loading to ensure that is able to be trusted for aircraft flight (safety of flight).

The LAM-R project is critical to the maintenance and sustainment of AM assets worldwide, as a testbed for this AM improvement initiative where qualification requirements of a LAM-R for H-60 Oil Cooler Assembly and T700 Gas Generator Turbine Shaft will be developed.

Impact on Warfighter:

  • Reduction of costs
  • Increased asset readiness
  • Increased supply visibility of Status and availability of resources

DOD Participation:

  • U.S. Army AMRDEC
  • U.S. Navy, NAVAIR (Patuxent)

Industry Participation:

  • Honeywell
  • Southwest Research Institute (SWRI) with assistance from Elevate Systems
  • NCMS

Benefit Area(s):

  • Cost savings
  • Repair turn-around time
  • Obsolescence management and continued maintenance capability
  • Improved readiness

Focus Area:

  • Additive/advanced manufacturing