6K Additive joins PADAM project for advanced aerospace materials development
August 30, 2024
6K Additive, a division of 6K, based in North Andover, Massachusetts, USA, has been selected by America Makes for its Powder Alloy Development of Additive Manufacturing (PADAM) project. Under the project, 6K Additive will work in partnership with project lead, Castheon Inc., a provider of Additive Manufacturing technologies for mission-critical space applications, based in Thousand Oaks, California, USA. The project is part of the $6M PADAM project funded by the Air Force Research Laboratory (AFRL).
The PADAM programme specifically targets the cost-efficiency and performance enhancement of Nb C-103 powder feedstock by qualifying an extended particle size distribution (PSD) for both Laser Beam Powder Bed Fusion (PBF-LB) and Directed Energy Deposition (DED) methods.
C-103 is a niobium alloy used in high-temperature applications. While C-103 has historical success in space-flight applications there are significant MRL maturation opportunities identified to improve productivity, affordability, material, and design maturity. This project is expected to improve material availability and decrease the cost for C-103 by expanding the supply base and utilising a broader range of particle size distribution (PSD).
Using PBF-LB in conjunction with DED, a wider range of PSD can be used, thus efficiently utilising more of the powdered C-103 produced. The selected final materials will undergo rigorous testing led by NASA Glenn Research Center and NSL Analytical. Lockheed Martin and Firefly Aerospace will serve as production transition partners, further maturing refractory AM materials for thermal protection systems and space propulsion applications.
“We are very excited to be working alongside Castheon, leading defence primes, and even other powder manufacturers to advance C-103 use in Additive Manufacturing for the defence industry,” said Frank Roberts, President of 6K Additive.
AM offers advantages for producing complex parts with improved performance and significant near-net shape capability with significant savings in production time. 6K Additive’s UniMelt microwave plasma process for producing powders, such as C-103 from revert sources, lowers cost and increases efficiency for high-temperature and space applications.
“We are embarking on an incredibly exciting era across the AM sector. Exploring the possibilities of AM material applications is a step in the right direction with considerable implications for the future of aerospace and defence,” stated Brandon Ribic, Technology Director at America Makes. “America Makes is incredibly fortunate to have the support of OSD ManTech and AFRL and the engagement of the brightest minds in the country who will be collaborating to revolutionise this technology.”
Greg Pilon, Chief Revenue Officer, ADDMAN added, “Working alongside 6K Additive and other industry leaders on this project allows us to push the boundaries of what’s possible. Castheon’s focus on advancing niobium alloys through AM not only improves material performance but also plays a critical role in strengthening our nation’s defence capabilities. We’re proud to contribute our expertise to this initiative.”
6K Additive is the world’s first producer of AM powder made from highly sustainable sources – offering a full suite of premium powders including nickel, titanium, copper, stainless steel, aluminium alloys, and refractory metals such as tungsten, niobium, and rhenium. Backed by the UniMelt production-scale microwave plasma process, the technology precisely spheroidises metal powders while controlling the chemistry and porosity of the final product with zero contamination with the $23M Department of Defense (DoD) award is a testament to the capabilities that 6K Additive has for upcycling scrap material into a premium powder suitable and accepted by the DoD for aerospace and defence applications.
