Hot Isostatic Pressing of Additively Manufactured Space-Use Components in Aluminum and Titanium

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Burloak Technologies is a supplier of precision engineered components and support services. It recently created a world leading additive manufacturing facility which is focused on components for the space sector. In the space industry, Hot Isostatic Pressing (HIP) is a vital post-process operation for cast and Additive Manufactured (AM) components. During HIP the metal is held at high temperatures and pressures to eliminate internal porosity and improve the material properties. The space industry is currently using the same basic HIP processes and control definitions established for low performance castings. These practices are far from optimum for highly critical and high-performance AM hardware. This limits the innovation possible with AM for the space industry. Burloak will soon complete installing Canada's only, commercial HIP vessel at its Oakville facility. The goal of this Alliance proposal is to create a partnership between Burloak and McMaster to develop "space-centric" HIP process specifications focusing on two strategic alloys for the space industry; Al10SiMg and Ti-6Al-4V. The proposed work will identify the optimal time-temperature-pressure cycles for components that are additively manufactured out of the above materials. It will also exploit the gas quenching capabilities of the state-of-the-art HIP vessel at Burloak to develop more efficient treatments that involve fewer processing steps. The proposed work will pursue the development of new Al alloys that are specifically designed to take advantage of AM processes and the specific capabilities of the Burloak HIP vessel. This would permit Burloak to eliminate several expensive heat-treatments steps. The proposed work will solidify Burloak's position in AM for the space industry. It will also fill a critical gap in Canada's space component supply chain. Presently, the absence of local facilities and expertise on HIP results in all Canadian space components being shipped overseas for processing. This poses a security risk to space-related controlled goods, as well as, resulting in a substantial increase in cost and lead times. The proposal will, therefore, aid the development of Canada's space industry. It will also train 3 HQP in this critical and expanding sector.