Jeff D. Haynes, Program Manager, Aerojet Rocketdyne
Additive Manufacturing has been infused into the Aerospace community as a new technology that can radically improve affordability, lead time and performance metrics. With any relatively new technology, discrete process details require detailed understanding which is then applied to part qualification methods and controls. This presentation approached the additive manufacturing technology in a risk-based manner that develops the powder, process and properties for each alloy before applying this to component and system level testing. To date, a number of subscale and even full scale engine validations have taken place with additive manufactured hardware. Conventional qualification methods have been applied while new, in-situ methods are being developed. An overview of the process details, inspection methods (and limits), component and system testing and future in-situ process control and part validation will be presented.