RESEARCH FOCUS AREAS

CCAM researchers solve current and complex manufacturing challenges in collaboration with their members in the following four research focus areas:

Additive Manufacturing (AM)

Process for creating a three-dimensional object in which material is deposited layer-by-layer under computer control.

In the case of additive manufacturing of metallic materials, two primary processes are used.  The Powder Bed Fusion (PBF) process utilizes a laser beam or electron beam, which is precisely scanned over a pre-deposited layer of powder causing local melting and solidification for each layer.  The PBF process is capable of very good feature resolution and surface quality and in many instances may be considered a net shape manufacturing process.  The Directed Energy Deposition (DED) process uses a laser, electron beam, or electric arc for deposition of powder or wire feedstock which is fed directly into the moving heat source to produce each layer.  The DED process typically uses higher energies for processing than the PBF process, which enables the DED to achieve higher deposition rates but also results in poorer feature resolution and surface finish.  The DED process may be easily scaled to large build volumes, may utilize multiple alloys during deposition, and is considered a near-net shape manufacturing process.

If you are considering AM for enhancing the performance of existing or new product designs, CCAM offers a full range of processing capabilities and engineering expertise to assist and support your decisions in design, process and material selection, and shop-floor integration of AM.  If you are currently utilizing AM, CCAM’s advancements in design-for-additive, process sensing technologies, and AM as a node in the intelligent factory offers you the opportunity to fully utilize AM technology, while also exploiting the digital manufacturing thread.

Expertise

material selection / process development / process sensing / product characterization / factory integration

Focus

integrated modeling tools / powder characterization / sensor instrumentation / process qualification / process reliability

Additive Manufacturing at Work

CCAM

Additive Manufacturing

Through our combined expertise in materials engineering, design and analysis, process sensing, metrology and characterization, and digital data management, we provide a full set of solutions for the development and implementation of additive manufacturing.  Whether you are working with the high precision of laser powder bed fusion or the versatile directed energy deposition process for producing large structures, CCAM has the facilities and capabilities to initiate or refine additive manufacturing for your products and manufacturing environment.

Mission

Provide a multidisciplinary and solutions-based approach for enabling and supporting implementation of advanced additive manufacturing technologies for our customers.

Value Proposition

  • Production-ready development of additive manufacturing processes
  • Readily available additive machine platforms in multiple formats
  • In-house expertise in materials, characterization, testing and simulation
  • Digital thread for additive infrastructure
  • Opportunities for federal matching funds

Capabilities and Services

Small-to-Large Scale Additive Research

  • A center of innovation and discovery
  • A membership-based collaborative research center
  • Production-ready manufacturing solutions
  • Transitioning additive to industry and government

Providing External Services

  • CT scanning of full-scale parts
  • Additive prototypes or preproduction lots
  • Characterization of metal powders
  • Additive mechanical testing: fracture, fatigue, strength
  • Fabrication of replaceable parts certified for service

Machining of Additive Parts

  • Machining protocols before and after heat treatment
  • Understanding machining of fit, converging features and cooling arrays
  • Multi-material part machining
  • Highly interrupted cutting
  • Near-net shape fabrication

Capabilities and Services:

Design and Production of Multi-Material Systems

  • New synthesis and processing methods
  • Computational materials tools
  • Novel microstructures
  • Material compatibility for repair and sustainment

Optimizing Additive Designs for Performance

  • Application of advanced lattice and cellular structures
  • Porous metals
  • Process parametric studies
  • Detailed fracture mechanics and corrosion testing and analysis

 

The Team

Yuri Plotnikov, Ph.D.
Kyle Snyder
Richard P. Martukanitz, Ph.D.
John Sions
Ben Zimmerman (Team Leader)

Interested?

Contact the CCAM Team today:
info@ccam-va.com | (804) 722-3700

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