America Makes
Corrosion of Additive – Tested At Component Scale (CATACS) – America Makes
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Additive manufacturing (AM) is of significant interest to the Department of Defense as it enables rapid, customizable production. However, AM qualification and certification for metal parts remain a barrier due to a lack of widely accepted testing and processing methods. Material properties produced from AM can differ from traditional manufacturing methods, leading to unique corrosion concerns. The CATACS program aims to establish and validate a framework for evaluating AM metal part corrosion testing needs, focusing on representative testing at the component scale in two critical areas: high-temperature environments and thermal management systems.
By addressing these gaps, the CATACS program looks to accelerate the adoption of AM parts in high-performance defense systems by establishing a reliable corrosion testing framework that streamlines certification, strengthening manufacturing readiness, and scaling the defense industrial base.
The CATACS request for proposal (RFP) is separated into two topic areas.
- Topic 1 – Corrosion of AM Components at Elevated Temperatures: Demonstrate corrosion performance of AM components requiring elevated temperature capability in representative environments beyond lab air, considering pressure-vessel conditions, fuel-air mixtures, differing surface exposures, and metallurgical interactions with adjacent components.
- Topic 2 – Corrosion of AM Components for Thermal Management: Demonstrate corrosion performance of metal AM thermal management components, focusing on interactions between AM microstructures and one or more working fluids under varying thermal conditions across complex geometries and flow channels.