Boeing Baseline Delta Qualification Program

Laser Powder Bed Fusion (LPBF) is a maturing manufacturing process and substantial work is still being conducted to fully control the process. One major challenge is that there are significant differences between different machine makes and models. These differences can be non-trivial and impact key process variables. Since the effect of these differences on the mechanical properties of the final product are not well understood, it is common for each machine to be treated as a separate stand-alone manufacturing system. As such, anytime a new machine type is placed into production, the amount of effort to verify and eventually qualify this new type of machine is quite significant due to the amount of data that must be replicated. The goal of this program is to demonstrate and document the level of effort required to “Delta Qualify” a new machine make and model into a family of already qualified machines under “Delta Qual Innovation” project call from America Makes. This program will begin by qualifying a known machine (EOS M290) to produce Ti6Al4V parts in accordance with the AMS7032 qualification procedure, and to bridge that qualification over to a new machine with different characteristics (Renishaw 500Q). Both qualifications will be compared to specification minimums generated on an EOS M290 for AMS7028 to gauge success. In this presentation, the framework used for this effort (i.e., installation, operation, and material qualifications) will be presented, and results will be provided in follow up talks. Concurrent with this effort, other organizations will be developing new and innovative methods to reduce the effort required to evaluate, understand and qualify a new machine. The outcome of the multiple programs will be a documented procedure to qualify new machines for LPBF production, and also new, innovative methods to reduce the level of effort conduct this qualification.