Direct laser freeform fabrication of high performance metal components

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.