Use of Laser Welding for Fabrication of Nickel Based Superalloy Aerostructures and Propulsion Components

TECHNOLOGY AREAS: Weapons; Space Platforms; Air Platform OBJECTIVE: This topic seeks to develop process parameters for laser welding of high performance Nickel based superalloy components for air and space structures and propulsion DESCRIPTION: This topic is intended to develop laser welding parameters for thicknesses greater than 0.25 inches of high temperature superalloys with high precision and repeatability when compared to electron beam welding. The offeror shall sufficiently develop the laser welding process for high performance Nickel based superalloys to conduct demonstrations to meet Air Force needs. Identification of manufacturing/production issues required to further improve cost, rates, availability, and safety, should be documented. PHASE I: The Phase I effort should demonstrate the following: laser welded samples of high performance Nickel based superalloys, the scientific and technical merit of laser welding compared to Electron Beam welding. Develop laser welding parameters for thicknesses greater than 0.25 inches of high temperature superalloys with high precision and repeatability. The offeror shall sufficiently investigate the laser welding process for high performance Nickel based superalloys to meet AF needs. Some of the tasks include but not limited to are : (1) Perform industry survey for equipment suppliers for laser welders, (2) Down select a robotic laser welding equipment supplier, (3) Develop laser welding process with and w/o filler metal wire and evaluate high performance Nickel based superalloy parts from casting, wrought, additive manufacturing, etc. and evaluate weldments. PHASE II: Under the Phase II effort, the awardee shall sufficiently develop the technical approach, product, or process in order to conduct a small number of relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. Some of the tasks include but not limited to are : (1) Perform industry survey for equipment suppliers for laser welders, (2) Down select a robotic laser welding equipment supplier, (3) Develop laser welding process with filler metal wire and evaluate materials (high temperature Nickle based super alloy casting, wrought, Additive Manufacturing, etc.) and evaluate weldments. PHASE III DUAL USE APPLICATIONS: The awardee will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. The expected scope but not limited to is : (1) Seamless integration with automation solution for workpiece handling, loading and unloading of components and created sub assemblies and (2) Implement digital engineering for real time parameter and data streaming for statistical process control (SPC) process data reporting and storage capability. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Cao, X., P. Wanjara, J. Huang, C. Munro, and A. Nolting. "Hybrid fiber laser Arc welding of thick section high strength low alloy steel." Materials & Design 32, no. 6 (2011): 3399-3413. 2. Gr nenwald, Stefan. "High Power Fiber Laser Welding of Thick Section Materials Process Performance and Weld Properties." (2019). 3. Jiang, Zhenguo, et al. "Comparative study on fiber laser welding of GH3535 superalloy in continuous and pulsed waves." Materials & Design 110 (2016): 728-739. KEYWORDS: Multi-axis robotic laser welding; laser welding of thick sections; high power laser welding; laser welding of Inconel alloys; laser welding of Haynes alloys; laser welding of airframes, laser welding of spaceframes