Development of Materials for Metallic Direct Digital Manufacturing

Metallic Direct Digital Manufacturing (MDDM), is based on layer-by-layer metal deposition and has been developed to a sufficient state of manufacturing readiness where production applications have emerged in niche industrial sectors. DDM processes in general require the use of raw materials that are either powdered metal or weld wire, both sources having been developed long before DDM processes emerged. Materials specifically designed for AM/DDM process have not been developed in the metals supply base. Keystone Synergistic Enterprises, Inc. is proposing to develop a raw material chemistry and condition specification beginning with Ti-6Al-4V alloy, tailored to DDM processes, and consistent with aerospace quality standards. In Phase I this process will be started with the generation of a draft specification for DDM Ti-6-4 raw material. From the Ti-6-4 foundation, Keystone will define the next high priority alloys for aerospace, nickel superalloys, high-strength aluminum, high-strength steel, and magnesium alloys.