Application of Novel Additive Manufacturing Techniques for Cost Reduction in Space Launch Vehicles

Abstract

Additive Friction Stir Deposition (AFSD) is a new type of Additive Manufacturing (AM) capable of high-rate deposition of aerospace aluminum. AFSD overcomes some drawbacks of other AM processes while still benefiting from an expanded design space and alternative sourcing options. AFSD is promising for the manufacture of large structural components but has drawbacks of its own. This project establishes a framework to evaluate the technical suitability and business case of AFSD. We assess the current state of AFSD and its potential application on a high-impact part. AFSD has demonstrated good grain structure and ductility in aluminum deposition. However, the strength of the material post-deposition is below that of high temper forgings commonly used in the industry. Solution heat treatments may close this gap. Small-scale heat treatment studies have exceeded strength benchmarks but lacks data statistical significance, and the process carries significant risks. If AFSD can overcome these technical challenges and mature its manufacturing systems, Cost-Benefit Analyses (CBAs) show that despite significant capital and development costs, AFSD has the potential to bring positive Net Present Value (NPV) to large aluminum structures in the space launch industry. Supply chain implications from vertical integration and increased sourcing options have the potential to drive additional value. In this paper, we propose an analysis framework and apply it to one application but anticipate other applications also justify the development of this enabling manufacturing technology.