This document discusses additive layer manufacturing (ALM) applications for space equipment. It describes four case studies of ALM applications: 1) copper foil gilded for antenna reflectors, 2) integral co-curing of ultra-light sandwich composites for antenna skins, 3) composite tanks and structures for launch vehicles, and 4) titanium brackets for antenna reflectors. It also discusses ALM processes, materials, Astrium's qualification logic for ALM parts, and the general status of ALM at Airbus and EADS. The document is confidential and its content is the property of Astrium.

1. ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH].
Christian Désagulier, Materials & Processes Expert
An ALM Qualification Logic Proposal
for Space Equipments
SIRRIS, Liege Science Park, Rue Bois Saint Jean 12, 4102 Seraing
2014, May the 13th
Current applications, trends and future developments of metal
Additive Manufacturing / 3DPrinting for space and aviation

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Introduction : 3 ALM school cases..
 Copper foil gilded for DGR telecom reflector antenna
 Integral Co-curing for ULR Ku sandwich (1 ply per skin,
without adhesive, < 1 kg/m2)
 Launchers CFRP composite Tanks
 Ti64 brackets EBMed for ULR Ka antenna reflector

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1st ALM case : Copper foil gilded for DGR antenna

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- 35 microns Copper foil annealed 1360 x 3500 mm
- 0,5 micron gilded
- NDI Gold thickness
- Sample traveler for adhesion tests
 more than 80’s flying since 1995 (i.e. 320 gilded copper foils)

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2d ALM case : Ultra-Light Reflector Ku antenna

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- Integral Co-curing : 1 ply per skin, without adhesive, sandwich < 1 kg/m2
- NDI (thermography, US) + curing cycle checking
- Mimic sample traveler (OOP/ Compression tests, micrographs)
 100s customized antenna reflectors in flight since 2000..

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13 May 2014 7
The well known Additive Layer
composite Manufacturing machines
CFRP based
 Filament winding
Tow placement
- Spherical tanks from Ø 0,3 m to 1 m
- Cylindral tanks & structures from Ø
3m up to 5,5m, H up to 12 m
3d ALM case : CFRP Launchers Composite tanks
& structures

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13 May 2014 8
100’s ALM tanks on civil and defence launchers, manufactured since
25 years..

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3d ALM case : Satellite Bi-axial Sun Sensor

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3d ALM case : Satellite Bi-axial Sun Sensor

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Sirris, 2014, May the 13h
Telemetry Support (TMTC) + Bi-Axial Sun Sensor (BASS) Ti64 node support
- Conventional design for back up need
- Quality audit of the manufacturer subcontractor and registration of the qualified EBM process
- Manufacturing according to registered process
- NDT & traveler samples checking
- Mast to CFRP tubes integration with bonding of the knot
- Mast to Satellite integration
 ATLANTIC BIRD 7, first ALM commercial application in GEO, launched on Tuesday the
27th of September 2011, delivered to the customer on the 23th of October..
3d ALM case : Satellite Bi-axial Sun Sensor

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ALM - One Technology But Several Processes
Powder Bed Wire feed
Ti64
Inconel
Stainless
steelsScalmalloy®
Maraging
Electron Beam
LASER
CMT
Ti64
Stainless
steels
INVAR ?
CrCo alloys
and High T° alloys
Al-Si-Mg
Alloys
HP-Al Alloys
(2xxx, 7xxx)

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General technical status@EADS
General technical status@AIRBUS
AIRBUS

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ASTRIUM Qualification logic
Two possible approaches
 Proof load test on each new built part, or on
one part per batch
 Validation of samples produced with the
parts
 Traceability
 NDI qualification
 High level Incoming inspection
“Conventional”
The long-term target
“Composite”
Interim approach during
ALM maturity development
 the choice depend on the maturity of processes and
considering volume of parts..
 Development of a specific qualification
logic, in particular on inspection and
verification methods, contributing to
increase of technical maturity
 Impact and sensitivity of process
parameters
 NDI qualification
 Raw material (powder) supply chain
qualification

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