Direct laser freeform fabrication of high performance metal components

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Abstract
This paper focuses on recent advances in direct freeform fabrication of high performance components via selective laser sintering (SLS). The application, known as SLS/HIP, is a low cost manufacturing technique that combines the strengths of selective laser sintering and hot isostatic pressing (HIP) to rapidly produce low volume or “one of a kind” high performance metal components. Direct selective laser sintering is a rapid manufacturing technique that can produce high density metal parts of complex geometry with an integral, gas impermeable skin. These parts can then be directly post-processed by containerless HIP. The advantages of in situ encapsulation include elimination of a secondary container material and associated container-powder interaction, reduced pre-processing time, a short HIP cycle and reduction in post-processing steps compared to HIP of canned parts. SLS/HIP is currently being developed under a DARPA/ONR program for INCONEL® 625 superalloy and Ti-6Al-4V, the demonstration components being the F-14 turbine engine vane and the AIM-9 missile guidance section housing base respectively.

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