The technical objective of this activity was to integrate COMOTI’s capabilities to develop an Additive Manufacturing process route in order to produce high density IN625 material using Lasertec 30SLM. To achieve the objective, proper process parameters had to be established and material testing had to be performed.

Despite the fact that Additive Manufacturing has evolved rapidly, the process presents more challenges compared to the conventional manufacturing technologies. Therefore, it was identified the necessity to establish for each individual machine a process route traceability in order to define the optimum process parameters and to ensure the process repeatability and reliability, combined with the machine capabilities and limitations, to meet the space industry requirements.

The technical objective have been reached during project implementation period. Appropriate process parameters (laser power, scanning speed, layer thickness, hatch distance, scanning strategy) were defined in order to produce a densification degree over 99.6% for IN625, using Lasertec 30 SLM. The conformity of new and recycled raw material was assessed. Post-processing heat treatment was established and performed in order to reduce the internal stresses level of the specimens and to generate a fully recrystallized material microstructure. Material properties assessment against specimen orientation in the building volume was done by room temperature tensile testing of fully heat-treated specimens.

The activity allowed the development of COMOTI’s capabilities and expertise in metal Additive manufacturing. A process traceability system was implemented toward space industry requirements in order to further address more complex shape parts manufacturing and testing.

Four proposals were prepared with the Romanian industry and submitted as follow-on activities within GSTP activity no. 1000027362. All proposals start at TRL3 and target a TRL 4 – TRL 5. The proposals objective is to design, manufacture and test complex metallic parts using additive manufacturing technology.