Technology Driven ·  Warfighter Focused

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Additive Manufacturing for New Build, Remanufacturing and Life Extension of Critical Weapon Systems Components

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OBJECTIVE / SOLUTION

This program seeks to develop and qualify additive fabrication and repair processes for Project Managers to accept resulting new and repaired components for use. By defining the design and manufacturing process data required to support repeatable and reliable additive manufacturing production, additive solutions for new build and existing hard-to-source weapons components can be offered. Three separate additive technology thrusts are supported by this effort: Cold Spray, Laser Engineered Net Shaping (LENS) and Direct Metal Laser Sintering (DMLS).

Achievements

• Successfully repaired M1 Abrams Suspension Arms via LENS, passing analysis tests and prepared for road testing
• Substantiation Data collected for Cold Spray component repairs, passing bond strength testing
• Established 4340 steel DMLS verification database showing additively manufactured sample properties match wrought materials

Benefits

• Cost savings through reclamation of damaged components currently housed at Corpus Christie Army Depot’s Storage, Analysis, Failure Evaluation and Reclamation (SAFR) site
• Alternate weapon component manufacturing methods increasing supply base and supplier competition
• Increased in-theater readiness through provision of new and repaired components

Transition and Weapon Systems / Secondary Items Impacted

• AH-64 Apache/UH-60 Blackhawk component repairs and transition through Corpus Christie Army Depot
• M1A1 Abrams component repairs and transition through Anniston Army Depot
• Subsequent transitions to PM customers for new build components

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