Ultrasonic Additive Manufacturing for Efficient Space Vehicles

The goal of this Phase I SBIR program is to demonstrate the use of Ultrasonic Additive Manufacturing (UAM) solid state metal 3D printing to create new and innovative materials that enable Space Launch System structures with superior mechanical properties and increased reliability, and validate these advancements with third party testing. Specifically, this effort will demonstrate technical feasibility and test proof of concept for: 1. 3D printing of dissimilar high temperature metals such as Inconel and steel in novel designs 2. Creation of gradient materials for multipurpose structures 3. 3D printing of metal matrix composites for selective reinforcement and lightweighting The UAM process has been refined to achieve high technology readiness levels in aluminum, copper, stainless steel, and titanium, and combinations of these materials. The extension of the UAM process to dissimilar combinations with Inconel, gradient materials, and metal matrix composites is challenging. Successful proof of concept of these innovations and elevation of one specific application to TRL 4, validated by third party testing, will be accomplished in Phase I. With NASA guidance, the project team Phase II plan is to select and develop functional prototypes of Space Launch System structures with the most successful Phase I results to illustrate efficient space vehicle concepts. A demonstration unit will be delivered to NASA for testing at the completion of the Phase II contract.

The project team intends to develop Ultrasonic Additive Manufacturing (UAM) manufacturing processes supporting the Space Launch System to create structures with superior mechanical properties and increased reliability. UAM-enabled structures are an important enabler for minimized touch labor and final assembly steps, increased reliability and reduced cost. UAM, by its nature, enables improved lead times by directly printing parts in one machine at one time, eliminating part movements from process to process (and vendor to vendor). The solid state UAM bond in conjunction with an additive / subtractive system allow for custom structures (eg - metal matrix composites) to be manufactured with reinforcing members in any three-dimensional configuration. These composites can be created directly on existing structures manufactured through other processes, resulting in launch structures with lower mass and improved process lead time. The solid state nature of the UAM bond allows for combining any metal combination without formation of brittle intermetallics. This enables layer by layer material changes for complex graded metal structures. This can directly lead to lighter structures with increased structural efficiency by combining multiple functions in one component.

The initial application of high performance UAM-enabled structures will likely be in NASA, defense and commercial space structure programs, in that order. This estimate recognizes the high performance technology leading nature of the organizations and their missions. The project team already services aerospace customers. Agreements with these customers uniformly prohibit publication of the details of our work with them.

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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