SBIR-STTR Award

Lattice Block Structures (LBS) are used to produce parts with higher specific stiffness than a solid but are difficult to produce. Electron Beam Melting (EBM)technology is capable of building LBS in a variety of configurations directly from a computer file using much thinner and stronger ligaments or wall sizes than cast LBS. EBM LBS are lighter, can be produced faster, and in more complex shapes than conventionally produced LBS. The flexibility of EBM allows a designer to tailor properties in orientations as needed and still reduce component weight. EBM titanium LBS are ideal for Naval applications as the material is extremely resistant to corrosion.

Benefit:
Designers will have the ability to tailor specific stiffness and weight, and change it as required throughout a part. Design changes and upgrades implemented as easily as changing a computer file. Commercial applications for tailorable specific stiffness range from higher performing military hardware to driver faces on golf clubs.

Keywords:
Electron Beam Melting, Electron Beam Melting, tailor properties, LBS, lattice block structures, thinner and stronger ligaments or wall sizes, complex shapes, higher specific stiffness, EBM

This project will develop the capability to produce naval missile lattice block structures for leading edge components using electron beam melted gamma phase titanium aluminide powder. This is a materials, process, and component development effort. Suitable powder will be purchased and electron beam melting process parameters developed to melt powder into near net shape coupons for properties testing. Modeling using these properties will be done to develop lattice block structures for candidate parts. Selected parts will be built and tested. Designs will be iterated and retested. The final design will meet requirements for missile structure leading edges for the SM-3 and SM-6 programs. Weight savings will be quantified and preparations for integration with production hardware will be started. Cost savings estimates will be made.

Benefit:
The Navy and DOD will have a new manufacturing method to produce light weight, high specific stiffness, high temperature parts at a lower cost and shorter delivery time. A lattice block structure of gamma phase titanium aluminide will allow increased performance where ever applied. Commercial application include turbine and internal combustion engine components.

Keywords:
Near Net Shape, gamma phase titanium aluminide, Electron Beam Melting, low cost., SM-6 dorsal fin leading edge, SM-3 Strake leading edge, Rapid Manufacturing, lattice block structures