Publications

Abstract not provided.

Aerospace designers seek lightweight, high-strength structures to lower launch weight while creating structures that are capable of withstanding launch loadings. Most 'light-weighting' is done through an expensive, time-consuming, iterative method requiring experience and a repeated design/test/redesign sequence until an adequate solution is obtained. Little successful work has been done in the application of generalized 3D optimization due to the difficulty of analytical solutions, the large computational requirements of computerized solutions, and the inability to manufacture many optimized structures with conventional machining processes. The Titanium Cholla LDRD team set out to create generalized 3D optimization routines, a set of analytically optimized 3D structures for testing the solutions, and a method of manufacturing these complex optimized structures. The team developed two new computer optimization solutions: Advanced Topological Optimization (ATO) and FlexFEM, an optimization package utilizing the eXtended Finite Element Method (XFEM) software for stress analysis. The team also developed several new analytically defined classes of optimized structures. Finally, the team developed a 3D capability for the Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) additive manufacturing process including process planning for 3D optimized structures. This report gives individual examples as well as one generalized example showing the optimized solutions and an optimized metal part.

The LENS Qualification team had the goal of performing a process qualification for the Laser Engineered Net Shaping{trademark}(LENS{reg_sign}) process. Process Qualification requires that a part be selected for process demonstration. The AY1E0125 D-Bottle Bracket from the W80-3 was selected for this work. The repeatability of the LENS process was baselined to determine process parameters. Six D-Bottle brackets were deposited using LENS, machined to final dimensions, and tested in comparison to conventionally processed brackets. The tests, taken from ES1E0003, included a mass analysis and structural dynamic testing including free-free and assembly-level modal tests, and Haversine shock tests. The LENS brackets performed with very similar characteristics to the conventionally processed brackets. Based on the results of the testing, it was concluded that the performance of the brackets made them eligible for parallel path testing in subsystem level tests. The testing results and process rigor qualified the LENS process as detailed in EER200638525A.

Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) is a layer additive manufacturing process that creates fully dense metal components using a laser, metal powder, and a computer solid model. This process has previously been utilized in research settings to create metal components and new material alloys. The ''Qualification of LENS for the Repair and Modification of Metal NWC Components'' project team has completed a Technology Investment project to investigate the use of LENS for repair of high rigor components. The team submitted components from four NWC sites for repair or modification using the LENS process. These components were then evaluated for their compatibility to high rigor weapons applications. The repairs included hole filling, replacement of weld lips, addition of step joints, and repair of surface flaws and gouges. The parts were evaluated for mechanical properties, corrosion resistance, weldability, and hydrogen compatibility. This document is a record of the LENS processing of each of these component types and includes process parameters, build strategies, and lessons learned. Through this project, the LENS process was shown to successfully repair or modify metal NWC components.