Robotic arc directed energy deposition (DED) additive manufacturing (AM) offers flexibility and affordability for manufacturing, adding features to, and repairing large metal components. Arc DED AM can be used to replace nickel aluminum bronze (NAB) and stainless steel (SS) castings on high-mix, low-volume, long-lead-time naval components. This project developed robotic arc DED technology for marine components. Several robotic gas metal arc (GMA) welding systems were transformed into DED system. A large-format, 11-axis hybrid DED gantry was developed and used to fabricate a large, hollow SS propeller blade prototype. Ongoing development requirements were identified for implementation.

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