Development, Test, and Evaluation of Additively Manufactured Flight Critical Aircraft Components

The Naval Air Systems Command (NAVAIR) initiated an additive manufacturing (AM) demonstration effort with the following objectives: to gain experience with AM and the associated post-processing; to establish an AM process to produce and test flight-critical aircraft components; and to begin assessing paths towards standards and certification. A V-22 nacelle link and fitting assembly was selected for the demonstration effort. The performance of the AM produced components was compared to the original components and their design requirements. With the limits of this effort, it was determined that with proper processing, it is possible for AM materials to have strength properties that are comparable to those of wrought materials. The link and fitting assemblies showed sufficient structural properties through test and were installed on a V-22 test aircraft for a limited duration flight test. The components were recently granted a flight clearance for extended operations subject to a recurring daily inspection.