Additive Manufacturing of C64 for Aerospace Gear Applications

Additive manufacturing (AM) is a novel process of fabricating components in a layer-by-layer method under the control of computer-aided design (CAD) information, rather than by the traditional use of casting molds and forming dies. By allowing for net-shape fabrication of highly complex geometries without molds or machining, this process offers the potential to reduce material usage, energy consumption, component cost, and fabrication time. While AM presents the unique opportunity to manufacture single components quickly, it also provides for the potential to examine the effects of individual design alterations on overall system performance. QuesTek has utilized its proven Integrated Computational Materials Engineering (ICME) methodology to adapt Ferrium® C64® steel for additive manufacturing, where the market availability of AM gear steels is very limited. QuesTek has demonstrated success in AM-processing of C64 using a laser-based powder bed technique, from procurement of powder through final test part fabrication. This production route is demonstrating the ability to fabricate a near-net shaped part at a reduced cost and significantly reduced lead time relative to conventional manufacturing routes, making it especially useful for rapid prototyping of new components.