Influence of Manufacturing Process Parameters on GRCop-42 Produced by Selective Laser Melting

Abstract This paper looks to explore how variances in printing process parameters affect the density, porosity, and mechanical properties of additively manufactured GRCop-42, ultimately providing additional testing for this novel material. Since increased porosity can be correlated to decreased part performance, it is imperative that additive manufacturing companies understand what combination of printing parameters in the Selective Laser Melting process result in near fully dense parts. GRCop-42 presents an opportunity for the aerospace industry to make significant advancement in liquid rocket engine design. Currently there have been few studies published concerning additively manufactured GRCop-42 outside of NASA, making additional testing on vendor specific processes paramount. The GRCop-42 specimens tested in this paper were provided by i3D-MFG, a metal additive manufacturing company based in Redmond Oregon. As to not compromise their specific testing parameter sets the specimens have been codified. From the testing conducted on additive manufactured GRCop-42 for this paper, it was shown that variances in printing process parameters had significant effects on the porosity, and consequently the mechanical properties. With the addition of post processes such as Hot Isostatic Pressing, near fully dense parts were achieved. The intention of this publication is to provide an initial understanding of this new material in an effort to support its broader use in academia and industry.