SenSigma Awarded NAVY STTR Phase II Award

Innovative additive manufacturing (AM) process for successful production of 7000 series aluminum alloy components using Smart Optical Monitoring System (SOMS)

SenSigma has been working with NAVY to find a solution to successfully produce 7000 series aluminum alloy aircraft components utilizing an innovative laser AM process. The high power density used for laser AM may cause selective vaporization of some alloying elements with a low fusion point such as lithium, magnesium, and zinc because of their higher equilibrium vapor pressure than aluminum. Selective vaporization of alloying elements can take place in laser AM, thereby reduce mechanical performances of components. NAVY has been seeking a novel process that should accurately control the thermal profile during component fabrication and reduce defects due to oxidation, thermal stresses, and a "Hot Tearing" effect. Resulting components should demonstrate microstructural and mechanical and dynamic properties equivalent to or better than traditionally produced parts and have minimal to no distortion. An innovative AM process should have the potential to improve operational readiness, reduce total ownership cost, and enable parts on demand manufacturing for Naval Aviation.

The University of Michigan is the institutional partner and will apply SenSigma’s SOMS for online diagnostics of defect, composition and phase transformation. SenSigma is the lead for the project.