Additive Manufacturing Component Certification Strategy

Abstract

The certification strategy for the selected component highlighted multiple challenges: firstly, the lack of international and agreed material allowables for AM Inconel 718, secondly, the usage of a known but yet to be standard technology such as AM-LPBF. Lastly, in accordance with FAA guidance, also the safety assessment of the selected component. This activity has covered a robust qualification program for both the L-PBF system involved in component production and the related Inconel 718 material. It has provided the minimum material properties required for the use of this alloy processed using the L-PBF process. This strategy included characterization of the mechanical properties of the material at high temperatures and following a thermal cycle as well as process related discontinuity. In this scenario a unique and innovative solution to powder reuse was proposed: instead of binding powder reuse to manufacturing lots, a multi-parameters powder control was developed.