SAE規格 AMS7032, 2022: Machine Qualification for Fusion-Based Metal Additive Manufacturing

Description

This standard has notes/guidance narratives interspersed throughout. These notes/guidance narratives are identified by a header and by text in italics.

This standard defines a series of requirements that results in a specific AM machine qualified to produce material (see GN1) in compliance to an aerospace materials specification. The machine control and/or configuration types are discussed in the next sections. The industry (including AIA and ASTM) generally acknowledges that there are three qualification milestones for AM machines; nevertheless, this document will focus only on the initial two stages, namely:

• Installation Qualification (IQ): Producing objective evidence to show that all key aspects of the process equipment and ancillary system installation adhere to the AM Part Producer’s specification and that the recommendations of the supplier of the equipment are suitably considered; this is tied to a specific machine serial number.

• Operational Qualification (OQ): Establishing sufficient process control to maintain stable material performance and demonstrating that the material specification requirements can be met; this is also tied to a specific machine serial number (see GN2).

[GN1] Guidance Notes:
For the purposes of this document, “material” refers to consolidated material produced during the AM process, not to be confused with the raw feedstock.

[GN2] Guidance Notes:
Qualification does not end with OQ. Discussion on the final qualification milestone, Performance Qualification (PQ) is outside the scope of this document, although an overview is provided in 9.1. Similarly, Material Qualification (MQ) is summarized in brief as part of the PQ process. It is important to note that each of these qualification milestones may have slightly different considerations based on the machine control and/or configuration types.

Machine Control Types
Fixed-Parameter Machines
Fixed-parameter machines are AM machines where the parameters are locked in at any point prior to initiation of the build cycle.

Adaptive-Parameter Machines
Adaptive-parameter machines are AM machines that operate with a control system that varies the parameters (during a build) within a fixed process window based on real-time feedback within the system. The overall qualification approach for adaptive-parameter machines is essentially the same as for fixed-parameter machines, but the adaptive control will drive a more in-depth process window development and analysis, as well as statistical process control (SPC) and perhaps other aspects. The specifics of how the approaches vary depend on the level of adaptive-parameter control, which parameters are adaptive, etc.

Machine Configuration Types
In general, this standard applies to powder bed fusion (PBF) and wire- or powder-fed directed energy deposition (DED) technologies. Plasma, electron beam or lasers are applicable energy source(s) for melting (see GN3).

[GN3] Guidance Notes:
At the time of this standard’s publication, these are the machine configurations that are covered:

Electron Beam Powder Bed Fusion (EB-PBF) - Additive manufacturing process in which thermal energy supplied by one or more electron beam(s) selectively fuses regions of a powder bed (refer to AMS7007).

Laser Powder Bed Fusion (L-PBF) - Additive manufacturing process in which thermal energy supplied by one or more laser(s) selectively fuses regions of a powder bed (refer to AMS7003).

Electron Beam Directed Energy Deposition-Wire (EB-DED-Wire) - Additive manufacturing process in which a focused beam of electrons is used to locally melt and deposit wire to form three dimensional shapes (refer to AMS7027).

Wire Fed Plasma Arc Directed Energy Deposition (PA-DED) - Additive manufacturing process in which focused thermal energy supplied by one or more plasma arc(s) is used to fuse wire by melting as it is being deposited (refer to AMS7005).

Laser Directed Energy Deposition with Wire (L-DED-Wire) - Additive manufacturing process in which focused thermal energy supplied by one or more laser(s) is used to fuse wire by melting as it is being deposited to form three-dimensional shapes (refer to AMS7010).

Laser Directed Energy Deposition with Powder (L-DED-Powder) - Additive manufacturing process in which focused thermal energy supplied by one or more laser(s) is used to fuse powder by melting as it is being deposited to form three dimensional shapes (refer to AMS7010).

Safety - Hazardous Materials
While the materials, methods, applications, and processes described or referenced in this standard may involve the use of hazardous materials, this standard does not address the hazards which may be involved in such use. It is the responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take necessary precautionary measures to ensure the health and safety of all personnel involved, while ensuring any hazardous waste generated is handled and disposed of in accordance with local regulatory requirements.