Aeromat passive vents 2015 02-11 with presentation notes
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Transcript of Aeromat passive vents 2015 02-11 with presentation notes
1© 2014 Lockheed Martin Corporation. All Rights Reserved
Additively Manufactured Vents for NASA’s Orion Exploration Flight Test 1
Andrew Clifton, Lockheed Martin
Roger Taylor III, Lockheed Martin
Alex Fima, RTI Directed Manufacturing
AeroMat 2015
2
Outline
• Introduction to Orion Exploration Flight Test 1• Design overview• Part characterization• Conclusions
3
Orion Exploration Flight Test 1
• Launched December 5, 2014
• Completed two orbits
• Max altitude 3,600 miles
• Re-entry at 20,000 mph with heat shield seeing up to 4,000 degrees Fahrenheit
4
Orion EFT-1 After Landing
Vent locations
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Part Details
• Purpose: – Venting of unpressurized
locations– Screen for foreign object
debris
• Features– Integral mesh (20 x 20, ~
50% open area, ~ 0.036 inch wide openings)
– Three mounting feet– Additional screens
welded on Integral mesh (in black)
Additional screens
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Manufacturing Process
• Made using Powder Bed Metal Laser Sintering process by Directed Manufacturing (Austin, TX)– Powder: Alloy 718 from Carpenter – Laser sintered– EOS M270 system, 200 watt laser, argon
purge• Stress relief, hot isostatic pressing, solution
heat treating, and aging were performed similar to ASTM F3055, Class F requirements
• Some machining after removal from baseplate
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Qualification Process
• Witness tension specimens – X, Y, and Z for each build
• Metallography to inspect for Laves phase• Vibration testing• 10x visual inspection of welds (not discussed)
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Surface Profile
• Test specimens had a roughness of approximately 100 Ra (arithmetical mean)
100x photo
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Microstructure
• No signs of Laves phase (undesirable interglobular phase)
• 50x photo on the right
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Tensile Strength
• Built 3 tensile specimens with each part – X, Y and Z
• Specimens were made as cylinders then machined to final dimensions
• 18 total specimens– Six specimens were not HIPed, solution heat
treated, or aged (for comparison purposes)– 1 was cross-sectioned for a non-
conformance• Tested per ASTM E8 at room temperature
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Tensile Strength
• All specimens met ASTM F3055, Class F requirements– Within 15% of minimum values
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Non-Conformances
• Build pause– Caused by power bump– Faint line visible
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Non-Conformances
• Build pause at 100x: Build direction
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Non-Conformances
• Build pause– Cross-sectioned Z (vertical)
specimen; no microstructural defect observed
– NASA Marshall Space Flight Center had representative data showing a slight reduction in yield strength (approximately 15%) and no reduction in ultimate tensile strength
– Parts were acceptable with assumed lower properties
Z tensile specimenwith build pause
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Non-Conformances
• Discoloration– Stress relieved in air by mistake– Cross-section of remnant material showed less than
0.001” oxidation– No embrittlement of mesh observed in vibration test
Vents installed in panel prior to integration
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Post-Flight Inspection
• No damage observed
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Conclusions
• Microstructure shows no signs of Laves phase• Tensile specimens met ASTM F3055, Class F
though they weren’t processed identically– Could have been made to near-net size
• Slight reduction in strength from build pause• Part passed a qualification vibration test• No damage observed after the mission
© 2014 Lockheed Martin Corporation. All Rights Reserved