Scalable Additive Friction Stir (AFS) for Multi-metal Deposition
ID: N24A-T023Type: Phase I
Overview

Topic

Scalable Additive Friction Stir (AFS) for Multi-metal Deposition

Agency

Department of DefenseN/A

Program

Type: STTRPhase: Phase IYear: 2024

Topic Link

https://www.sbir.gov/node/2479625

Additional Information

https://www.defensesbirsttr.mil/SBIR-STTR/Opportunities/
Timeline
    Description

    The Department of Defense (DOD) is seeking proposals for a Small Business Innovation Research (SBIR) program focused on the topic of "Scalable Additive Friction Stir (AFS) for Multi-metal Deposition". The objective of this research is to develop a portable or scaled-down friction stir deposition system that can structurally repair spot sizes or through holes down to 0.25" in diameter on 0.125" thick aluminum, titanium, and high-strength steel.

    Friction stir deposition is an emerging solid-state metal additive manufacturing process that allows for large-scale metal additive manufacturing, cladding, and structural repair. However, current commercial systems are not suitable for repairing small components on Navy and Marine Corps aircraft, which often have localized damage areas of less than 1". Additionally, the current systems are too large and not practical for remote or portable use on aircraft.

    The project will be conducted in two phases. In Phase I, the goal is to develop a concept for a friction stir deposition system that can deposit aluminum, titanium, and high-strength steel in areas less than 1 square inch on 0.125" thick substrates. Relevant machine parameters and deposition data will be captured to support modeling and model development. A Phase II testing plan will also be prepared.

    In Phase II, a prototype friction stir deposition system will be constructed and the material properties of the deposition of aluminum 7050-T7451, Ti6-4, and AerMet 100 alloys will be assessed. The properties of repaired substrates using feedstock of the same alloys will also be evaluated. A report documenting the design of the prototype system, system performance, and material testing results will be provided. A Phase III plan for prototype evaluation will be prepared, and the prototype system will be delivered to the Navy for evaluation.

    In Phase III, a full friction stir deposition system will be assembled and demonstrated to meet key deposition and material parameters, including mechanical properties related to strength and fatigue. The final deliverables will include a comprehensive report containing the design, deposition, and process and testing data, as well as the delivery of the full friction stir deposition system to the Navy.

    The development of a scalable or portable friction stir deposition system with multi-metal capability would have applications in the in-situ repair of commercial structures for aviation and other vehicle platforms.

    The solicitation notice can be found at this link. For more information, visit the Department of Defense SBIR/STTR Opportunities website.

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