AddUp Achieves Top Ranking in USAF Fatigue Study for Inconel 718 Additive Manufacturing

AddUp, a leading additive manufacturing company based in Cébazat, France, has emerged as the top performer in a high-cycle fatigue (HCF) study conducted by the United States Air Force (USAF). The study, which was part of the Small Business Innovation Research (SBIR) program, aimed to develop manufacturing, heat treatment, and surface finishing guidelines for Inconel 718 (IN-718) components in additive manufacturing. IN-718 is a critical material used in aerospace and defense, where high fatigue resistance is essential for ensuring structural integrity and long-term reliability.

Focus of the Study: Heat Treatment, Printing Parameters, and Surface Finishing
The study, led by REM Surface Engineering, investigated how different heat treatment and printing parameter combinations impacted the mechanical properties of additively manufactured IN-718 components. The research evaluated critical conditions such as the effectiveness of Hot Isostatic Pressing (HIP) versus non-HIP treatments, contour versus non-contour melting strategies, and various build angles (0°, 45°, and 90°). The aim was to optimize the material’s tensile strength and fatigue life, particularly for mission-critical applications.

AddUp’s Superior Performance with Surface Finishing Technology
AddUp was identified as vendor #1 (V1) in the study, outperforming other participants, especially when its FormUp 350 system was paired with REM Surface Engineering’s surface finishing technology, the Extreme ISF Process. This combination resulted in significantly enhanced material properties. AddUp’s FormUp 350 uses fine powder and roller recoater systems to produce high-quality surface finishes, which are critical for improving fatigue strength. REM’s surface finishing process further strengthened these properties, enhancing both corrosion and fatigue resistance, which is essential for aerospace components.

The Significance of Fatigue Resistance in Aerospace and Defense
The study’s results highlight the importance of fatigue resistance in aerospace and defense applications, where the reliability of components is crucial to mission success. The combination of advanced additive manufacturing and surface finishing technologies is shown to improve the overall performance of IN-718 components. By improving the fatigue life and reducing material degradation, these advancements help extend the lifespan of components, lower maintenance costs, and reduce downtime in high-stress environments like aerospace and defense sectors.

Implications for Future Aerospace Applications
Dr. Augustin Diaz, Advanced Manufacturing and Innovation Manager at REM Surface Engineering, noted the value of the study for both the Department of Defense (DoD) and the broader additive manufacturing industry. “The results from this research not only benefit the DoD but also provide valuable insights for advancing additive manufacturing in aerospace and defense,” he said. The study’s findings on the synergy between AddUp’s PBF-LB technology and REM’s surface finishing processes are expected to influence future developments in the production of high-performance aerospace components.