Durability and Damage Tolerance Assessment of Additively Manufactured (AM) Parts and AM Repairs

The certification requirements associated with additively manufactured (AM) parts and AM repairs, such as cold spray and wire arc additively manufactured (WAAM), are required to be consistent with MIL-STD-1530D and US the Joint Services Structural Guidelines (JSSG)-2006. The U.S. Air Force (USAF) requirements for AM parts and AM repairs are delineated in USAF Structures Bulletin (SB) EZ-19-01, which states that “the most difficult challenge is to establish an accurate prediction of structural performance related to durability and damage tolerance (DADT)”. Structural Bulletin EZ-19-01 also states that “The focus on DADT requirements is emphasized in this SB because it contains the greatest challenges”. Consequently, the primary aim of this research is to develop a fundamental understanding of this problem space, specifically focusing on the durability of AM parts and AM repairs.