Item Requirements
Article Name: Additive Manufacturing of Copper Alloy Test Article Using
Single-mode Continuous Green Laser Powder Bed
Fusion (PBF) Equipment
1. Overview
This task involves manufacturing a test article using copper al oy powder
through powder bed fusion (PBF) additive manufacturing technology
employing a single-mode continuous green laser, and conducting material
property evaluations on the fabricated specimen.
2. Contract Method
Contract Period: Ninety (90) days after Effective Date of Contract (EDC)
Estimated Budget: USD 18,350.00
Method of Contract: restricted competitive bid (the lowest bid price)
Qualification bidding documents (must be submitted by the bidding deadline
and verified prior to bid opening/qualification review)
o
Evidence of technical capabilities for task execution (patents related to
Green Laser PBF equipment)
o
Test report for copper alloy (CuCrZr) manufactured using in-house
equipment (meeting Requirement 1 specified in Section 3.3) 3.
Detailed Task Description
3.1 Design/Manufacturing Plan Preparation & Kick-off Meeting
(within 2 weeks after contract)
Submit production design and schedule after discussing task details.
Specify inspection items, methods (including equipment and standards), and
performing agencies (or company) for test article and specimens.
Hold a kick-off meeting to discuss details after establishing the manufacturing
process and schedule.
Proposed Master Plan
(The manufacturer must submit a detailed plan)
o
26.06
- Prepare detailed Design/Manufacturing plan prior to contract signing.
- Conduct kick-off meeting immediately after contract signing (discuss
proposed Design/Manufacturing plan).
- Document and report DfAM/analysis results, fol owed by meeting.
- Start additive manufacturing after finalizing the printing geometry.
o
26.07
- Perform inspection and measurement after additive manufacturing
completion, submit results report.
- Begin post-processing and prepare for strength/leak testing (share
progress by stage).
- Perform specimen testing and submit results analysis report.
o
26.08
- Perform strength/leak testing (request client's on-site visit and
observation) and ship delivery items to client.
3.2 DfAM Geometry and Process Design
Review AM feasibility using 3D CAD model provided by the client.
Perform DfAM(design for additive manufacturing) geometric design for the
final design proposal and share model file (.prt, .stp, .stl, etc.).
Predict deformation via simulation prior to printing.
Establish strategies to minimize deformation (support, orientation, process
parameters, compensation design, etc.).
Create machining drawings for interface work after printing.
The DfAM process and results must be documented and approved by the
client before proceeding with additive manufacturing. Additive manufacturing
must be able to initiate within two weeks of receiving approval for the
documented DfAM design. The start of additive manufacturing must occur
within one month of contract execution.
Discuss design changes required for AM and finalize the design.
3.3 Additive Manufacturing(L-PBF)
Deliverable: test article, 1 set
Dimensions: ~340 mm x Dia. 170 mm (Detailed drawings provided after
contract).
Material: CuCrZr (for PBF)
o
Secure material certificates and perform basic inspections (shape,
composition, size distribution, flowability, etc.).
Requirements:
1.
Must be manufactured as a single piece using single-mode continuous
green laser PBF equipment, through a process satisfying the fol owing
conditions: density 99.98%, tensile strength 510MPa, yield strength
410MPa, elongation at break 20% (test in accordance with ASTM E8).
2.
Using a single-mode continuous green laser PBF printer, print 4 round
bars for tensile testing (same height as the test article) simultaneously
with the test article (2 inside, 2 outside the test article).
3.
Submit photos and videos documenting the entire process (printing,
machining, inspection, measuring, test, etc.), with the video submitted
as a time-lapse video (30~60 seconds).
3.4 Post-Processing
Powder Removal & Inspection:
o
Completely remove internal powder before additional work, verify via
RT (Radiographic Test) and CT (Computed Tomography).
o
Submit powder removal results (RT, CT video-based report) for
approval. Check for defects like Shrinkage Lines (SL) or Pin Holes via
visual inspection.
o
Proceed with re-manufacturing or fol ow-up processes upon agreement
with the client depending on defects.
o
Measure dimensions in the as-printed state and submit a comparison
report against the 3D CAD model used for printing and build simulation
result.
Stress Relief & Wire Cutting:
o
Perform sandblasting, stress relief heat treatment, and wire cutting
according to the manufacturer's standards.
o
Remove supports from the test article before/after wire cutting.
Strengthening Heat Treatment & Tensile Testing:
o
Perform heat treatment on the test article and round bars according to
the manufacturer's standard for CuCrZr heat treatment.
o
Machine 4 tensile specimens per one round bar (number may vary
based on SL location).
o
Machine the specimens so that the layer where SL or other defects are
identified becomes the measurement location for the tensile test.
o
Perform the tensile test (at room temperature).
o
Test tensile specimens using tensile testing equipment within its
inspection validity period, as specified in the manufacturing plan
proposal and confirmed at the manufacturing kick-off meeting (If
equipment is changed, a written justification must be submitted and
approved by the client.).
o
The tensile test results are submitted to the client in report format
(including tables and graphs).
o
Criteria: Individual tensile test results must achieve at least 90% of the
reference values. Results below 90% are deemed manufacturing
defects, requiring agreement with the client to determine subsequent
process actions. Reference values may be adjusted to target values
provided by the manufacturer with the client's approval.
Test Article Inspection & Machining:
o
Perform additional visual inspection (including inner wal ) and
sandblasting for surface roughness improvement after separation from
BP.
o
Perform dimensional measurements (using a coordinate measuring
machine, CMM) on wire-cut test article to verify machining reference
surfaces.
o
Based on the measured dimensions, revise the machining drawings
(including tool drawings), obtain approval from the client, and perform
the shape machining. After machining is complete, perform
dimensional measurement (using a 3D measuring machine, CMM) on
the machined areas.
o
If measurements are to be performed using equipment possessing
equivalent precision instead of CMM, approval from the client must be
obtained.
3.5 Assembly & Testing
Assembly:
o
Secure fittings and caps, and mount them on the test article after
machining is complete to enable testing.
o
The contractor must also prepare al necessary fittings, plugs, gaskets,
pressure strength/leak test plugs and fixtures for the test article, and
fastening bolts/nuts for the test article ports.
Strength & Leak Testing:
o
Strength Test: Pressurize both flow path to 10 bar each (maintain at
10 bar intervals for 60 seconds each, avoid rapidly increasing pressure
in one flow path to prevent hardware damage), then pressurize to 90
bar and maintain at 90 bar for 5 minutes. Attach dial gauges to
measure deformation.
o
Leak Test 1: Pressurize both flow path to 10 bar each (maintain at 10
bar increments for 60 seconds each, avoid rapid pressure increases in
one channel to prevent hardware damage), then pressurize to 60 bar
and hold for 5 minutes to verify leak tightness (check internal pressure
measurement or presence of bubbles in the water tank, etc.).
o
Leak Test 2: Pressurize flow path to 10 bar (maintain at 10 bar
increments for 60 seconds each, avoid rapid pressure increases in flow
path to prevent hardware damage), then pressurize to 30 bar and hold
for 5 minutes to verify leak tightness (check internal pressure
measurement or presence of bubbles in the water tank, etc.). This test
is performed individually for each flow path (to verify the absence of
leakage between flow paths).
o
Strength/leak tests shal be conducted in principle by preparing a test
procedure sheet, obtaining approval prior to the test date, and
performing the test in the presence of the client(preferably visit the
manufacturer during 3D printing or strength/leak testing). If client
attendance is not possible, the test process shal be captured and
recorded, and the video provided.
o
The strength test involves placing the test article on a stable surface
and attaching dial gauges or similar devices to areas susceptible to
deformation to measure the amount of deformation.
3.6 Delivery
After production and testing are completed, the test article must be completely
dried to remove al internal and external moisture. It must then be fil ed with
helium (or nitrogen) or equivalent protective measures must be taken to
prevent moisture ingress.
Pack securely to prevent damage during transport.
Deliver all components used in the strength/leak test, including the caps and
fasteners.
Submit original manufacturing drawings and photographic documentation as
original files.
Submit the original data for al measurements, instrumentation, and tests.
