SAE International (SAE), the global association of engineers and related technical experts in the aerospace, automotive and commercial-vehicle industries, in collaboration with Norsk Titanium (Norsk), the global leader in additive manufacturing of aerospace-grade titanium components, developed the world’s first specifications for Directed Energy Deposition (DED) additive manufacturing.
These specifications are based on Norsk’s Rapid Plasma Deposition™ (RPD™) process and material requirements. These specifications will be crucial for all additive manufacturing professionals across the world. The SAE Aerospace Materials Specifications (AMS) documents will shortly be available to a broader base of users around the globe.
DED Additive Manufacturing Specifications
The specifications are developed by SAE’s Additive Manufacturing Committee (SAE AMS-AM). They establish the minimum basic requirements for the procurement of RPD™ Preforms from Norsk by any aerospace or non-aerospace customer. In addition, these specifications support the regulatory certification process by ensuring consistent process and quality control.
The SAE AMS-AM was established by aerospace industry leaders in 2015. It continues to develop aerospace material specifications (SAE AMS) for metal and polymer AM to support the needs of the aerospace industry.
David Alexander, Director, Aerospace Standards at SAE International spoke about the guiding specifications, “Given that advanced materials and advanced manufacturing are strategic focus areas for SAE International, we continue to support the aerospace industry’s advances and adoption of additive manufacturing technologies. As well as contributing vital technical expertise, Norsk Titanium played a leadership role as document sponsor in the development of the groundbreaking new specifications and along with the other AMS-AM output, these new material and process specifications help address the regulatory authorities’ request for guidance material for this critical emerging technology.”
It is believed that the release of AMS7004 Titanium Alloy Preforms from Plasma Arc Directed Energy Deposition Additive Manufacturing and AMS7005 Wire Fed Plasma Arc Directed Energy Deposition Additive Manufacturing Process are milestone achievements for the metal additive manufacturing industry.
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Collaboration with Norsk Titanium
Norsk Titanium’s RPD™ is the world’s first FAA-approved, 3D-printed, structural titanium, delivering substantial lead-time and cost savings for aerospace, defense, and commercial customers.
Through the RPD process, titanium wire is melted and built up in layers to a near-net-shape component in an inert, argon gas environment. The process is monitored more than 600 times per second for quality assurance. According to Norsk, the component requires less machining and has a 50 to 75 percent improvement in “buy-to-fly” ratio – or the weight of raw material compared to the weight of a finished part – compared with conventional manufacturing methods.
Speaking on the new specifications, Norsk President and CEO Michael Canario said, “Our engineers have thoroughly enjoyed working with the SAE team to validate our proprietary process with the engineering community. RPD™ is truly a disruptive process to the current subtractive manufacturing industry with wide benefits supporting not only the supplier but the end-user.”
About Norsk Titanium: Norsk Titanium AS is the world’s pioneering supplier of aerospace-grade, additively manufactured, structural titanium components. The company is distinguished in the aviation industry by its patented Rapid Plasma Deposition™ (RPD™) process that transforms titanium wire into complex components suitable for structural and safety-critical applications.
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