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Joint Metal Additive Database Definition (JMADD): Baseline Qualification and Expansion Activities

Federal Aviation

Administration

Joint Centers of Excellence for Advanced Materials

John Tomblin, Rachael Andrulonis, Royal Lovingfoss, Neville Tay

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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Research Team & Objectives

Brandon Saathoff

Senior Engineering Manager, Advanced Materials Research

Lauren Tubesing

Business Development Leader, Advanced Manufacturing Strategy

Mark Shaw

Chief Engineer, Defense Industrial Base Strategy

Rachael Andrulonis

Director of Advanced Materials Research

John Tomblin, PhD

Senior Vice President for Industry and Defense Programs,

WSU-NIAR Executive Director

Neville Tay

Research Engineer, Advanced Materials Research

Eathan Devine

Research Engineer, Advanced Materials Research

Royal Lovingfoss

Director of Advanced Materials Lab

Slide:

Cindy Ashforth

Senior Technical Specialist for Advanced Composite Materials

Ahmet Oztekin, PhD

Advanced Materials Research Program Manager, JAMS Program Manager

Kevin Stonaker

Technical Monitor

Michael Gorelick

Chief Scientific and Technical Advisor for Fatigue and Damage Tolerance

Dustin Avery, PhD

Senior Research Engineer, Advanced Materials Research

PROJECT OVERVIEW

Project Partners:

Boeing, Beehive Industries, 3DS (specimen fabrication), ELCAN (powder sieve & blend), ATI, AP&C, & Tekna (powder suppliers), 100+ Public advisory committee members, 33 government steering committee members

PROJECT OBJECTIVES

Establish a framework for developing statistically significant material databases of metal AM materials.
Expand the framework to additional AM machine types, powder reuse and other changes in the manufacturing process.
Generate allowables (T90 and T99) and specifications for Ti64 grade 5 across multiple L-PBF machine types and material-machine combination for publication in MMPDS.

Brian Schmidt

Program Manager & Laboratory

Operations Director

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FAA JAMS – Metal AM | Program Overview

Milling vs Grinding

Generate data on 4^th JMADD machine for dataset inclusion.
Development of fatigue curves for various post processing conditions.

Investigate feature-level performance debits for AM test articles via static test characterization.

Investigate as-printed surface design values and bulk material inspection methods on fatigue sensitive LPBF components.

Qualification of new alloy/process of interest to the FAA and related industry.

Baseline qualification program for Ti-6-4/EOS M290

Jointly funded with America Makes

JMADD

Joint Metal Additive Database Definition

M-JMADD

JMADD Expansion

M-JMADX

Building Block

M-BBFLP

Surface Inspection

M-MASFI

New Alloy/Process Qualification

M-NANPQ

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Overview Ti-6Al-4V Grade 5 Projects

Test Type	Number of specimens tested (across orientations and test temperatures)					5 machine total specimen count	MMPDS
	NIAR (M290)	Beehive (M290)	Boeing (M290)	NIAR (GE-M2) (in-process)	3D Systems (DMP Flex 350) (in-process)		MMPDS
	NIAR (M290)	Beehive (M290)	Boeing (M290)	NIAR (GE-M2) (in-process)	3D Systems (DMP Flex 350) (in-process)		C- and D-Basis Mandatory Requirements x 3 orientations (XY, ZX45, ZX)	Recommended Properties (Not Mandatory)
E8 – Tension	369	292	104	132	132	1029	100 x 3 = 300 Across 5 machines, 10 heats
E9 – Compression	175	143	51	66	66	501	100 x 3 = 300 Across 5 machines, 10 heats
B769 – Shear	174	148	54	66	66	508	100 x 3 = 300 Across 5 machines, 10 heats
E238 – Bearing	146	134	45	180	180	685	100 x 3 x 2 (two e/D ratios) = 600 Across 5 machines, 10 heats
E399 – Fracture Toughness	154	130	39	36	36	395		30 x 3 = 90 Across 3 machines, 3 heats
E606/466 – Fatigue	143	113	48	108	-	412		Recommended Load control: 6 test per stress ratio (R), 3 stress ratios, no minimum heat or lot requirements Strain control: 10 tests for Rg = -1.0, 6 tests other strain ratios

JMADD (3 machines)

JMADX (4^th machine)

JMADD fifth machine

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JMADD Qualification Process Chain

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JMADD Material and Process Specifications

Slide

Titles:

NFS 064 - NCAMP Feedstock Specification: Titanium-6 Aluminum-4

Vanadium for Additive Manufacturing

NAPS 065 - NCAMP Additive Process specification for Laser Powder Bed Fusion
NTP-AM-1064Q1 - NCAMP Material Property Data Acquisition and Qualification Test Plan for Additively Manufactured Titanium-6Aluminum- 4Vanadium
NPCD 81064 - Process Control Document for Additive Manufacturing of Titanium-6 Aluminum-4 Vanadium with Laser Powder Bed Fusion on a 3D Systems DMP Flex 350
NPCD 81065 - Process Control Document for Additive Manufacturing of Titanium-6 Aluminum-4 Vanadium with Laser Powder Bed Fusion on an EOS M290
NPCD 81066 - Process Control Document for Additive Manufacturing of Titanium-6 Aluminum-4 Vanadium with Laser Powder Bed Fusion on a GE M2 Series 5
NAMS 064 - Standard Specification for Additive Manufacturing of

Titanium-6 Aluminum-4 Vanadium with Laser Powder Bed Fusion

Status:

Draft material and process specifications authored ahead of qualification activity. Specifications to be finalized at the conclusion of data analysis.

In-Work

Posted on NACMP

Portal

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Reporting Deliverables

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Organization	Report/Specification	Contents	Status	Completion date
NCAMP	NAPS 065 - NCAMP Process specification (Rev A)	This document defines the minimum requirements for control of the L-PBF process.	Rev A Uploaded to NCAMP Portal Revision in process	-
	NFS 064 - NCAMP Feedstock Specification (Rev A)	This document provides the required test methods and specification limits for all feedstock powder.	Rev A Uploaded to NCAMP Portal Revision in process	-
	NAMS 064 - NCAMP Material specification (Rev A)	This additive specification establishes the requirements for the finished printed material properties of LPBF Ti64.	Rev A Uploaded to NCAMP Portal Revision in process	-
	NPCD 81064 - NCAMP Process Control Document (Rev C)	Process Control document for EOS M290	Rev C Uploaded to NCAMP Portal Revision in process	-
	NPCD 81065 – NCAMP Process Control Document (Draft)	Process Control Document for 3DS DMP 350	NCAMP AER review	-
	NPCD 81066 - NCAMP Process Control Document (Draft)	Process Control Document for GE M2	NCAMP AER review	-
	NTP-AM-1064Q1 - NCAMP Test Plan (Rev C)	Outlines number of specimens required for each test type	Rev C Uploaded to NCAMP Portal	-
	NCAMP Material Property Data Report	Compilation of all raw data with summary statistics (mean, SD, and CoV)	First Draft In Review by NCDMM	Q3 2026
FAA	FAA Technical Report- Parameter Comparison Study	Results and recommendation on Site comparison study	In queue for AFRL release	Q2 2026
FAA	FAA Technical Report on Lessons Learned and Guidelines	JMADD fatigue results, statistical guidelines, and lessons learned throughout project (prequal and qual)	In process (NIAR)	Q4 2026
America Makes	1^st Revision of Baseline JMADD Report on Static and Physical Properties Future revisions will be made to this report to include: JMADD 5^th machine results JMADD Fatigue + Corrosion results	Final report including objective, methodology and summary graphs and tables of test results (prequal and qual) with basic statistics (mean, SD, COV)	1^st revision Submitted to NCDMM NIAR Revision In process	1^st Revision Complete

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JMADD Testing Status

Updates:

All JMADD baseline testing have been completed
NIAR is in the process of compiling all reduced-fatigue test results for the JMADD final reporting.
Based on feedback received from industry on fatigue curve generation, NIAR currently drafting and reviewing guidance documentation/standards for fatigue curve generation and its use for allowables.

Pre-Qualification (Task 1) Virgin powder fabrication	Qualification 1 (Task 2) Virgin powder fabrication	Qualification 2 (Task 3) Reuse (50/50) blend fabrication
Parameter Comparison Study	Static mechanical testing	Static mechanical testing
Orientation Down-selection study	Physical property testing	Physical property testing
Site comparison study	Room temperature LCF and HCF	Room temperature LCF and HCF
	Grain Size Analysis	LCF @ 600°F testing
	LCF @ 600°F testing	Grain Size Analysis

Completed

In-progress

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JMADD Next Steps & Summary

Next Steps:

Revise and update NCAMP program documentation (i.e., material specification, feedstock specification.) and distribute to steering committee for review.
Carry out statistical analysis (i.e., Monte Carlo Simulations, MMPDS & CMH-17 methods) when data from all five machines are available.
NIAR to compile and review fatigue guidelines white paper with the FAA team.

Benefit to Aviation:

Standardized qualification framework which can be applied to new metal AM material.
Publicly available material allowables for L-PBF Ti-6Al-4V grade 5 material.

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FAA JAMS – Metal AM | Program Overview

Milling vs Grinding

Generate data on 4^th JMADD machine for dataset inclusion.
Development of fatigue curves for various post processing conditions.

Investigate feature-level performance debits for AM test articles via static test characterization.

Investigate as-printed surface design values and bulk material inspection methods on fatigue sensitive LPBF components.

Qualification of new alloy/process of interest to the FAA and related industry.

Baseline qualification program for Ti-6-4/EOS M290

Jointly funded with America Makes

JMADD

Joint Metal Additive Database Definition

M-JMADD

JMADD Expansion

M-JMADX

Building Block

M-BBFLP

Surface Inspection

M-MASFI

New Alloy/Process Qualification

M-NANPQ

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Page 11

Agenda

Objective and Status updates
Tests properties and updates
Powder Feedstock Chemistry
Preliminary Test Results
Preliminary Statistics Results
Lessons learned and Next Steps

JMADX: Task 1 (JMADD 4^th Machine)

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JMADX: Task 1 (JMADD 4^th Machine)

Current Status:

Qualification fabrication in progress (14 of 17 builds fabricated).
Post-processing for fabricated build in progress.
First draft of NPCD for 4th machine in review by PAC team (NIAR waiting for feedback).
Qualification testing in progress.

Objective:

To generate L-PBF fabricated Ti-6Al-4V (grade 5) data to enable the creation of a C/D-basis material allowable for MMPDS and an A/B-basis NCAMP material specification. Broad dissemination across the aerospace industry will inform design allowable value generation.

This fabrication matrix is identical to the 5th JMADD machine project

Reuse (50/50 blend) powder builds
Site	Powder	Lot	Build Design	Build ID
NIAR	Tekna	1 lot	D11	M12
			D12	M13
			D13	M14
			D11	M15
			D12	M16
			D13	M17
			D14	M18

Virgin powder builds
Site	Powder	Lot	Build Design	Build ID
NIAR	Tekna	1 lot	D11	M2
				M3
				M4
			D12	M5
				M6
				M7
			D13	M8
				M9
				M10
			D14	M11

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Virgin powder fabricated specimens	Reuse (50/50) blend fabricated specimens
Mechanical testing:	Mechanical testing:
Tension (E8/E21)	Tension (E8/E21)
Shear (B769)	Shear (B769)
Compression (E9/E209)	Compression (E9/E209)
Bearing (E238)	Bearing (E238)
Fracture Toughness (E399)	Fracture Toughness (E399)
Physical testing:	Physical testing:
Density (B311)	Density (B311)
Thermal Conductivity (E1530)	Thermal Conductivity (E1530)
Specific Heat Capacity (E1269)	Specific Heat Capacity (E1269)
Thermal Diffusivity (E1461)	Thermal Diffusivity (E1461)
Coefficient of Thermal Expansion (E831)	Coefficient of Thermal Expansion (E831)
Microstructure	Microstructure
Fatigue testing:	Fatigue testing:
Low Cycle Fatigue	Low Cycle Fatigue
High Cycle Fatigue	High Cycle Fatigue

Tests Completed

Testing In-progress

Machining in-progress

Tension, shear, and compression tests are conducted at room temperature and at elevated temperatures of 300 °F, 500 °F, 700 °F, and 900 °F.
Preliminary results gathered will be presented in the following slides

JMADX: Task 1 (JMADD 4^th Machine) Testing Status

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NSL Analytical (Reuse) powder testing results

4^th machine Powder feedstock (Boxed in Red) composition in comparison with JMADD.
Before-blend (B-blend) powder test results were within ASTM and AMS specification requirement.

Virgin	From powder supplier
B-blend	1 time reuse powder
Reuse	50/50 blend of Virgin and B-blend

Check Analysis limits (AMS2249K)

JMADX: Task 1 (JMADD 4^th Machine)

			CHEMICAL COMPOSITION (wt. %) - Ti BALANCE
Supplier	Lot #	Powder State	Al	V	Fe	Y	C	O²	N	H²	OTHERS EACH	OTHERS TOTAL
ATI	Lot 1	Virgin	6.03	4.02	0.21	< 0.0009	0.006	0.149	0.013	0.0009
		B-Blend	6.24	4.10	0.19	< 0.001	0.007	0.160	0.014	0.0008	< 0.05	< 0.1
		Reuse	6.13	4.05	0.20	< 0.0010	0.013	0.160	0.011	0.0010	< 0.05	< 0.10
	Lot 2	Virgin	6.12	4.06	0.22	< 0.0009	0.007	0.142	0.0120	0.0006
		B-Blend	6.14	4.06	0.20	<0.001	0.005	0.150	0.0070	0.0007	<0.05	<0.1
		Reuse	6.26	4.13	0.19	< 0.001	0.008	0.140	0.0096	0.0010	< 0.05	0.036
	Lot 3	Virgin	6.01	4.12	0.21	< 0.0009	0.008	0.145	0.014	0.0010
		B-Blend	6.15	4.08	0.20	< 0.001	0.006	0.160	0.014	0.0008	< 0.05	< 0.1
		Reuse	6.16	4.14	0.20	< 0.0010	0.010	0.160	0.012	0.0010	< 0.05	< 0.10
	Lot 4	Virgin	6.3	4.01	0.21	< 0.0009	0.006	0.160	0.0060	0.0009
		B-Blend	6.26	3.99	0.19	<0.001	0.005	0.170	0.0036	0.0009	<0.05	<0.1
		Reuse	6.43	4.06	0.18	< 0.001	0.007	0.170	0.0065	0.0010	< 0.05	0.026
	Lot 5	Virgin	6.31	3.94	0.15	< 0.0009	0.029	0.178	0.030	0.0010
		B-Blend	6.29	3.94	0.15	< 0.001	0.030	0.200	0.026	0.0006	< 0.05	< 0.1
		Reuse	6.35	3.96	0.15	< 0.0010	0.031	0.190	0.023	0.0011	< 0.05	< 0.10
	Lot 6	Virgin	6.22	3.86	0.15	< 0.0009	0.040	0.188	0.036	0.0009
		B-Blend	6.34	3.93	0.14	<0.001	0.037	0.190	0.020	0.0009	<0.05	<0.1
		Reuse	6.49	3.99	0.13	< 0.001	0.038	0.200	0.030	0.0011	< 0.05	0.037
AMS 7015 (Class A)			5.50 - 6.75	3.50 - 4.50	≤ 0.30	≤ 0.005	≤ 0.08	0.11 - 0.20	≤ 0.05	≤ 0.015	≤ 0.10	≤ 0.40
ASTM F2924			5.50 - 6.75	3.50 - 4.50	≤ 0.30	≤ 0.005	≤ 0.08	≤ 0.20	≤ 0.05	≤ 0.015	≤ 0.10	≤ 0.40

			CHEMICAL COMPOSITION (wt. %) - Ti BALANCE
Supplier	Lot #	Powder State	Al	V	Fe	Y	C	O²	N	H²	OTHERS EACH	OTHERS TOTAL
AP&C	Lot 1	Virgin	6.41	4.03	0.22	< 0.001	0.010	0.14	0.0100	0.0020	< 0.10	< 0.40
		B-Blend	6.66	4.08	0.21	< 0.001	0.015	0.16	0.0140	0.0016	< 0.05	< 0.10
		Reuse	6.48	4.04	0.22	< 0.001	0.016	0.15	0.0086	0.0017	< 0.05	< 0.10
	Lot 2	Virgin	6.31	3.96	0.2	< 0.001	0.010	0.14	0.010	0.0020	< 0.10	< 0.4
		B-Blend	6.35	3.97	0.2	<0.001	0.013	0.14	0.0058	0.0016	<0.05	<0.1
		Reuse	6.41	4.01	0.19	< 0.001	0.014	0.14	0.013	0.0016	< 0.05	0.027
	Lot 4	Virgin	6.38	4.16	0.21	<0.001	0.010	0.15	0.020	0.0010	< 0.10	< 0.40
		B-Blend	6.44	4.11	0.16	<0.001	0.014	0.15	0.019	0.0017	<0.05	<0.1
		Reuse	6.44	4.16	0.20	<0.001	0.013	0.14	0.016	0.002	<0.05	<0.1
Tekna	Lot 1	Virgin	6.13	4.05	0.17	< 0.005	0.009	0.12	0.0070	0.0020	< 0.05	< 0.05
		B-Blend	6.35	4.22	0.17	<0.001	0.008	0.13	0.0088	0.0030	< 0.05	< 0.1
		Reuse	6.32	4.26	0.19	< 0.001	0.010	0.14	0.0052	0.0029	< 0.05	< 0.10
	Lot 2	Virgin	6.39	4.23	0.18	< 0.005	0.010	0.13	0.0070	0.0020	< 0.05	< 0.05
		B-Blend	6.44	4.15	0.18	< 0.001	0.008	0.16	0.0170	0.0020	< 0.05	< 0.1
		Reuse	6.37	4.17	0.19	< 0.001	0.010	0.16	0.0065	0.0022	< 0.05	< 0.10
	Lot 4	Virgin	6.18	4.06	0.16	< 0.001	< 0.005	0.12	0.0090	0.0040	< 0.02	< 0.05
		B-Blend	6.32	4.03	0.16	< 0.001	< 0.005	0.13	0.0110	0.0035	< 0.05	< 0.1
		Reuse	6.32	4.07	0.17	< 0.001	0.006	0.14	0.0099	0.0037	< 0.05	< 0.10
	Lot 5	Virgin	6.17	4.00	0.17	< 0.001	0.007	0.12	0.0090	0.0040	< 0.01	< 0.05
		B-Blend	6.40	4.08	0.15	< 0.001	0.010	0.14	0.0140	0.0034	< 0.05	< 0.1
		Reuse	6.32	4.05	0.15	< 0.001	0.009	0.13	0.013	0.0041	< 0.05	< 0.1

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ASTM E8 - Room Temperature (75°F)

ASTM E8/E21 - Elevated Temperature Test Results

219 data points across 18 EOS M290 builds and 6 DMP Flex 350 builds across 4 different virgin & reuse AP&C powder lots.
Data not normal (Stnd. Skewness out of ±2 range).
Levene’s test P-value ≥ 0.05. There is not a statistically significant difference amongst the standard deviations at 95% confidence interval.
ANOVA P-value ≤ 0.05 (Significant difference between the mean at the 95.0% confidence level).

JMADX: Task 1 (JMADD 4^th Machine) Tension Results

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41 data points across 6 GE M2 builds from same virgin Tekna powder lot
Data approximates a normal distribution
Levene’s test P-value ≤ 0.05. There is statistically significant difference amongst the standard deviations
K.W P-value ≤ 0.05 (Significant difference between the medians )

Build to build

41 data points across 6 GE M2 builds from same virgin Tekna powder lot
Data approximates a normal distribution
Levene’s test P-value ≥ 0.05. There is not a statistically significant difference amongst the standard deviations
ANOVA P-value ≥ 0.05 (No Significant difference between the mean )

Laser 1 vs Laser 2

Build Orientation

41 data points across 6 GE M2 builds from same virgin Tekna powder lot
Data approximates a normal distribution
Levene’s test P-value ≥ 0.05. There is not a statistically significant difference amongst the standard deviations
ANOVA P-value ≤ 0.05 (Significant difference between the mean )

JMADX: Task 1 (JMADD 4^th Machine) Tension Results

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44 data points across 6 3DS builds from same virgin AP&C powder lot
Data approximates a normal distribution
ANOVA P-value ≤ 0.05 (Significant difference between the mean )
Levene’s test P-value 0.0836. There is not a statistically significant difference amongst the standard deviations

Build to build

44 data points across 6 build plate locations across 6 3DS builds
Data approximates a normal distribution
ANOVA P-value ≥ 0.05 (No Significant difference between the mean )
Levene’s test P-value 0.6174. There is not a statistically significant difference amongst the standard deviations

Location on Build Plate

Build Orientation

44 data points across 3 build orientations across 6 3DS builds
Data approximates a normal distribution
ANOVA P-value ≤ 0.05 (Significant difference between the mean )
Levene’s test P-value 0.7815. There is not a statistically significant difference amongst the standard deviations

JMADX: Task 1 (JMADD 4^th Machine) Tension Results

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Pivot Chart across 5 JMADD Machines (Tensile)

	NIAR (EOS M290)	Beehive (EOS M290)	Boeing (EOS M290)	NIAR (GE-M2)	3DS DMP Flex 350
Number of E8 Specimens Tested (n)	352	280	92	41	44
Avg. Tensile Ultimate Strength (ksi)	161	161	154	153	159
Avg. Tensile Yield Strength (ksi)	149	149	142	141	146
Avg. Elongation at Fracture (%)	16	16	17	19	18
CoV for Tensile Ultimate Strength (%)	3.4	3.0	0.8	1.2	0.8
CoV for Tensile Yield Strength (%)	4.2	3.6	1.5	1.4	1.3
CoV for Elongation (%)	10.2	9.7	10.0	4.2	5.3

Red “boxed” data were fabricated with ATI lot 12 and 15 (powder lots with oxygen % below 0.11%).
Strength of specimen fabricated with out of specification powder performed lower in terms of tensile strength

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Allowables Comparison with Tensile Data across 5 Machines

		MMPDS (MIDAS)					CMH-17 ANOVA method				CMH-17 Non-Parametric				AMS 4992 �Investment Castings�		AMS 4934�Extrsuion - Solution treated and aged�		AMS 4928�bar and die forging�		AMS 7028�Ti-6Al-4V, Hot Isostatically Pressed (Low Temperature, High Pressure), Produced by Laser Powder Bed Fusion
		EOS M290 (x3) n=724		5 Machine n=809			EOS M290 (x3) n=724		5 Machine n=809		EOS M290 (x3) n=724		5 Machine n=809		Thickness <0.500		Thickness <0.500		0.5-1.0		E8 specimen 3
Property	(orientation)	T99	T90	T99		T90	T99	T90	T99	T90	T99	T90	T99	T90	T99	T90	T99	T90	T99	T90	Minimum tensile properties
Ultimate Tensile Strength	(XY)	149	152	148		152	146	152	146	152	148	154	148	153	125	129	155	163	135	142	150
	(XY45Z)	148	152	150		154	146	152	146	152	149	153	150	154
	(Z)	148	152	149		154	147	153	146	152	150	155	150	153							151
Yield Strength	(XY)	135	138	135		139	132	138	132	138	134	140	135	139	111	116	138	147	125	134	136
	(XY45Z)	135	138	136		140	132	139	132	140	136	140	137	140
	(Z)	137	141	135		142	135	142	134	142	139	144	137	142							140
Elongation (%)	(XY)	11	13	11		13	12	13	11	13	10	13	10	13							11
	(XY45Z)	10	13	12		14	12	14	12	14	12	13	12	16
	(Z)	14	16	14		16	15	16	15	16	13	16	13	16							14
		ATI-12 and 15 removed N = 706		ATI-12 and 15 removed N = 791			ATI-12 and 15 removed N = 706		ATI-12 and 15 removed N = 791		ATI-12 and 15 removed N = 706		ATI – 12 and15 removed n = 791
		T99	T90	T99	T90		T99	T90	T99	T90	T99	T90	T99	T90
Ultimate Tensile Strength	(XY)	150	152	150	153		147	152	146	152	150	154	150	154
	(XY45Z)	150	154	151	154		146	152	147	152	150	154	150	154
	(Z)	151	155	150	154		147	153	146	153	151	155	150	154
Yield Strength	(XY)	136	138	137	139		132	138	132	138	136	140	137	140
	(XY45Z)	136	141	137	141		132	139	133	139	137	141	137	141
	(Z)	141	144	137	143		136	142	134	141	140	144	137	142
Elongation (%)	(XY)	11	13	11	13		12	13	11	13	9	13	10	13
	(XY45Z)	10	13	12	14		12	14	12	14	12	13	12	16
	(Z)	14	16	14	16		15	16	15	16	13	16	13	16

PRESENTED ALLOWABLES ARE NOT FINAL!

Note: Secondary test speeds for tensile test used in JMADD and AMS7028 are different. Secondary speed in JMADD is 0.1 in/in/min. and AMS7028 were tested using 0.05 in/in/min. Comparisons are only for informational purposes.

T99 and T90 calculated omitting specimens (18) fabricated by ATI powder lot 12 and 15 Oxygen (wt%) was below 0.11% (out of specification per AMS 7015)

JMADD data still meets MMPDS C/D basis requirements even after removing out of spec data points.

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TUS Probability Plots for JMADD XY Orientation specimens

Probability plots shown were extracted from Midas software

Normal Probability plot

Weibull Probability plot

T99 = 150 ksi

T90 = 153 ksi

The probability plots shown above are for TUS of XY orientated specimens across all 5 JMADD machines, with ATI lot 12 excluded (n=791).
The plots above were utilized to generate the T99 and T90 values in the previous table on slide 11.
JMADD TUS (XY orientation) data across all 5 machines machine appears to be bimodal and not normal.

T99 = 147 ksi

T90= 152 ksi

T99 = 150 ksi

T90= 153 ksi

Normal method

Censored Normal method

T99 = 146 ksi

T90= 152 ksi

ANOVA Method

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ASTM E9/E209 - Elevated Temperature Test Results

87 data points across 7 EOS builds and 3 GE M2 builds across 4 different virgin & reuse Tekna powder lots.
Data not normally Distributed
Levene’s test P-value ≤ 0.05. There is a statistically significant difference amongst the standard deviations.
K.W. P-value ≤ 0.05 (Significant difference amongst the medians at the 95.0% confidence level).

ASTM E9 – Compression Yield Strength (75°F)

JMADX: Task 1 (JMADD 4^th Machine)

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ASTM B769 - Room Temperature (75°F)

ASTM B769 - Elevated Temperature Test Results

88 data points across 7 EOS builds and 3 GE M2 builds across 4 different virgin & reuse Tekna powder lots.
Data not normally distributed
Levene’s test P-value ≤ 0.05. There is statistically significant difference amongst the standard deviations.
K.W P-value ≥ 0.05 (No Significant difference between the medians at the 95.0% confidence level)

JMADX: Task 1 (JMADD 4^th Machine)

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Low cycle fatigue data (Run out 1 million)

High cycle fatigue data (Run out 10 million)

All LCF specimens were strain controlled for first 50k cycles (5 Hz), then switched to load control (20 Hz).

JMADX: Task 1 (JMADD 4^th Machine) Fatigue Results

FAA JMADX program fatigue results will be overlaid onto these plots before April 28.

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ASTM B311 Test Setup Picture

81 data points across 72 EOS M290 builds, 3 GE M2 builds, and 3 DMP Flex 350 builds across all JMADD powder lots.
Test result shows that there is a consistency between all sites and powder feedstock used.
Ti64 density of Bar/Forgings from MMPDS Volume I reports a density of 0.16 lb/in³ (4.43 g/cc)

Fabricator	Average [lb/in³]	Standard Deviation	COV [%]
3DS DMP Flex	0.1596	0.0000	0.0000
GE-M2	0.1594	0.0002	0.1280
EOS M290 (Beehive)	0.1598	0.0001	0.0630
EOS M290 (Boeing)	0.1598	0.0001	0.0365
EOS M290 (NIAR)	0.1597	0.0005	0.2956

More Density data to follow

JMADX: Task 1 (JMADD 4^th Machine) Density Results

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Next Steps:

NIAR to address PAC/GSC members comments and feedback received on NCAMP 4^th machine PCD (NPCD 81066 was shared with PAC on 11/12/25).

NIAR to continue remaining reuse (blend) build fabrication.

NIAR will continue post-processing all fabricated qualification specimens and prepare them for testing.

NIAR will continue testing all fully machined specimens and incorporating reduced test data in monthly/quarterly updates as it is received.

Benefit to Aviation:

Standardized qualification framework which can be applied to new metal AM material.
Publicly available material allowables for L-PBF Ti-6Al-4V grade 5 material.

JMADX: Task 1 (JMADD 4^th Machine)

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JMADX: Task 2 (Alternate Post Processing Fatigue Study)

Slide: 26

Approach:

Create common mixed-orientation build design for fabrication and performance comparison across builds.
Fabricate specimens on EOS M290 from one Tekna Powder Lot.
Post-process and machine per test matrix definition.
Generate fatigue curves for comparison to JMADD baseline.
Include E8 static tensile lot release, density, thermal, and microstructure specimens on each build.
Stress levels/Strain levels utilized will be identical across all conditions.
XY As-Fab surface condition specimen geometry determined with trial prints (0.1” hole diameter).

As-fab XY (with 0.1 inch through Hole)

Machined ZX

Machined XY As-fab ZX

As-fab XY

Fatigue	R-ratio	Stress levels	Finish	Heat Treat (Group)	Orientation	Number of stress levels x Specimens per stress level	Specimens tested
						RTA (70°F)
				VSR	XY	5 x 3	15
					ZX	5 x 3	15
				(A)
			Machined	VSR+ Alt HIP (B)	ZX	5 x 3	15
					XY	5 x 3	15
LCF	-1	55% 60% 65% 70% 75%		Straight to HIP (G)	XY	5 x 3	15
					ZX	5 x 3	15
			As Fab	VSR (C)	XY	5 x 3	15
					ZX	5 x 3	15
				VSR+ Alt HIP (D)	ZX	5 x 3	15
					XY	5 x 3	15
				Straight to HIP	XY	5 x 3	15
					ZX	5 x 3	15
				(F)
				VSR + 200 MPa HIP	XY	5 x 3	15
				(E)	ZX	5 x 3	15
						Total	210

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JMADX: Task 2 (Alternate Post Processing Fatigue Study)

Surface Finish	Heat Treat	Orientation	Avg. 0.2% Offset Yield Strength (ksi)	Avg. Tensile Ultimate Strength (ksi)	Avg. Elongation of fracture (%)	Avg. Reduction of Area (%)
As-printed	VSR (A)	ZX	154.60	165.16	9.48	15.79
	VSR + 815°C, 200 Mpa (E)	ZX	144.79	155.62	13.91	16.83
	HIP only (F)	ZX	146.25	157.05	15.96	19.64
Machined	JMADD Data	ZX	150.43	160.92	17.37	40.10

Preliminary Tensile Test Results

Preliminary X-ray CT Data (12-micron Voxel Resolution)

As-printed XY(VSR)

As-printed (VSR +200 Mpa HIP)

Tensile and fatigue testing across heat treat and surface finish in progress.

As-printed (VSR)

Heat Treat	Surface Condition	Max Porosity (%)	Maximum Porosity Length (um)
VSR only (A)	As-printed	0.00537	443
VSR + 815°C, 200 Mpa (E)	As-printed	0.00041	231
VSR + 920°C, 200 Mpa (D)	As-printed	0.00005	100
HIP only (F)	As-printed	0.00030	159

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JMADX: Task 2 (Alternate Post Processing Fatigue Study)

Slide: 28

Project Status:

Microstructure specimen preparations in progress.
All fabricated and machined specimens are in queue for testing (tension and fatigue).

Next Steps

Subset of specimens will be sectioned to measure cross sectional area, evaluate alpha case depth, and microstructure.
Conduct tension testing for remaining heat treat and surface condition specimens, followed by LCF testing.

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					Status/Updates
R-ratio	Stress levels	Finish	Heat Treat (Group)	Orientation	Tension Data	Fatigue Testing	Microstructure & Alpha Case Evaluation
-1	55%� 60%� 65%� 70%� 75%	Machined	VSR (A)	XY	In-queue	Not started	In-queue
			VSR (A)	ZX	In-queue	Not started	In-queue
			VSR + HIP-2 (920°C, 200 Mpa) (B)	ZX	In-queue	Not started	-
			VSR + HIP-2 (920°C, 200 Mpa) (B)	XY	In-queue	Not started	In-queue
			Straight to HIP-1 (815°C, 200 Mpa) (G)	XY	In-queue	Not started	-
			Straight to HIP-1 (815°C, 200 Mpa) (G)	ZX	In-queue	Not started	In-queue
		As printed	VSR (C)	XY	In-queue	Not started	-
			VSR (C)	ZX	Completed	In-queue	In-queue
			VSR+HIP-2 (920°C, 200 Mpa) (D)	ZX	In-queue	Not started	In-queue
			VSR+HIP-2 (920°C, 200 Mpa) (D)	XY	In-queue	Not started	In-queue
			Straight to HIP-1 (815°C, 200 Mpa) (F)	XY	In-queue	Not started	In-queue
			Straight to HIP-1 (815°C, 200 Mpa) (F)	ZX	Completed	In-queue	In-queue
			VSR+HIP-1 (815°C, 200 Mpa) (E)	XY	In-queue	Not started	-
			VSR+HIP-1 (815°C, 200 Mpa) (E)	ZX	Completed	In-queue	In-queue

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JMADD Fatigue Data Results

Low cycle fatigue data (Run out 1 million)

High cycle fatigue data (Run out 10 million)

All LCF specimens were strain controlled for first 50k cycles (5 Hz), then switched to load control (20 Hz).

FAA JMADX program fatigue results will be overlaid onto these plots before April 28.

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Questions?

Contact:

Neville Tay – neville.tay@idp.wichita.edu
Royal Lovingfoss - royal.lovingfoss@idp.wichita.edu
Rachael Andrulonis – rachael.andrulonis@idp.wichita.edu

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Acknowledgment: This material is based on research sponsored by Air Force Research Laboratory under Agreement Number FA8650-20-2-5700. The U.S. Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon.

Disclaimer: The views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of Air Force Research Laboratory or the U.S. Government.

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Following are backup slides

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Build to Build Variation across Virgin and Reuse from same powder lot

70 data points across 6 builds from same Tekna powder lot 2 (4 Virgin builds, 2 Reuse Builds)
Data approximates a normal distribution
ANOVA P-value = 0.0001 (Significant difference between the mean )
Levene’s test P-value 0.8622. There is not a statistically significant difference amongst the standard deviations

74 data points across 8 builds from same Tekna powder lot 1 (6 Virgin builds, 2 Reuse Builds)
Data approximates a normal distribution
ANOVA P-value = 0.0001 (Significant difference between the mean )
Levene’s test P-value 0.669. there is not a statistically significant difference amongst the standard deviations

82 data points across 8 builds from same AP&C powder lot 2 (6 Virgin builds, 2 Reuse Builds)
Data approximates a normal distribution
ANOVA P-value = 0.0001 (Significant difference between the mean )
Levene’s test P-value 0.7594. there is not a statistically significant difference amongst the standard deviations

NIAR Builds

Boeing Builds

Beehive Builds

Reuse

FAA JMADD 4^th Machine whiskers plots to be added before April 28.

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Machine to Machine variability

Interstitial elements across 6 powder lots (5 virgin and 1 reuse):

Oxygen 0.142% - 0.15%
Nitrogen 0.009% - 0.02%
Carbon 0.006% - 0.022%

Results

161 data points across 14 builds (6 Beehive builds, 8 NIAR Builds) were analyzed.
Data not normal (Stnd. kurtosis out of ±2 range)
K.W. P-value = 0.902 (there is not a statistically significant difference amongst the medians at the 95.0% confidence level)
Levene’s test P-value 0.4656. there is not a statistically significant difference amongst the standard deviations at the 95.0% confidence level.

Interstitial elements across 8 ATI powder lots (6 virgin and 2 reuse):

Oxygen 0.188% - 0.20%
Nitrogen 0.023% - 0.039%
Carbon 0.031% - 0.044%

Results

114 data points across 12 builds (6 Beehive builds, 6 NIAR Builds) were analyzed.
Data approximates a normal distribution.
K.W. P-value = 0.144 (there is not a statistically significant difference amongst the medians at the 95.0% confidence level)
Levene’s test P-value 0.0212. there is a statistically significant difference amongst the standard deviations at the 95.0% confidence level.

FAA JMADD 4^th Machine whiskers plots to be added before April 28.

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JMADD Lessons Learned

Room Temperature Mechanical Properties: The room temperature static mechanical properties across different fabricators show strong consistency, with coefficients of variation (CoV) ≤ 6%. The observed scatter trends align closely with those seen in Ti-6Al-4V wrought products as reported in MMPDS.
Impact of Powder Lot Composition on Strength: It was found that powder lots with higher interstitial elements, particularly oxygen and nitrogen, resulted in increased strength properties seen in both Qual 1 and Qual 2. This suggests that controlling powder composition can influence the strength characteristics of the final printed parts (see slide 8).
Strength-Ductility Trade-Off: Specimens with higher strength properties exhibited a lower reduction in gauge section area during tensile testing, coupled with a decrease in fracture toughness. This finding supports the well-known strength-ductility trade-off, where increasing material strength can lead to reduced ductility and toughness.
Elevated Temperature Performance: Elevated temperature test results for L-PBF Ti-6Al-4V showed similar performance to the percent knockdown data reported by MMPDS, further validating the material's high-temperature behavior and reinforcing the consistency of Ti-6Al-4V properties across different manufacturing methods and conditions.
Elemental Composition Changes After Powder Blending: After blending reuse with virgin powder, changes were observed in the elemental composition, particularly in oxygen and iron contents. This highlights the importance of closely monitoring and controlling elemental composition when reusing or mixing powder lots to ensure material consistency.
Physical Properties Consistency: The physical properties, such as density and hardness, exhibited comparable results between different powder lots and fabricators, suggesting that the variability in physical properties is minimal and within acceptable ranges.
Variability Across Builds and Machines: Build-to-build variability was observed across the three fabricators (see slide 7) when powder lot was kept constant. However, it was observed that there were no significant difference between machine-to-machine comparisons when powder lots with similar chemistry were used.

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