ASTM F3635-23
(Specification)Standard Specification for Additive Manufacturing – Finished Part Properties – Standard Specification for Niobium-Hafnium Alloy UNS R04295 via Laser Beam Powder Bed Fusion for Spaceflight Applications
General Information
- Abstract
SCOPE
1.1 This specification covers additive manufacturing of parts manufactured via laser beam powder bed fusion (PBF-LB) processing of niobium-hafnium alloy used in spaceflight applications. Parts made using this processing method are typically used in applications that require mechanical properties like wrought products. Products built to this specification may require additional post-processing in the form of machining, polishing etc. to meet necessary surface finish and dimensional tolerances.
1.2 This specification is intended for the use of purchasers or producers, or both, of PBF-LB R04295 parts for defining the requirements based on classification methodology. These requirements shall be agreed upon by the part supplier and purchaser.
1.3 Users are advised to use this specification as a basis for obtaining parts that will meet the minimum acceptance requirements established and revised by consensus of committee members.
1.4 User requirements considered more stringent may be met by the addition to the purchase order.
1.5 Units—The values stated in SI units are to be regarded as the standard. Other units are included only for informational purposes.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
- Status
- Published
- Publication Date
- 31-Oct-2023
- Technical Committee
- F42 - Additive Manufacturing Technologies
- Drafting Committee
- F42.07 - Applications
Overview
ASTM F3635-23 is the standard specification developed by ASTM International for the additive manufacturing of parts using Niobium-Hafnium Alloy UNS R04295 via Laser Beam Powder Bed Fusion (PBF-LB). This standard is specifically tailored for spaceflight applications, where parts must achieve mechanical properties comparable to wrought products. ASTM F3635-23 provides comprehensive guidelines for material selection, process qualification, microstructure, mechanical properties, non-destructive evaluation, quality management, and part certification. It enables suppliers and purchasers to define and agree upon manufacturing requirements to ensure parts meet critical aerospace and spaceflight performance needs.
Key Topics
- Material Scope: Applies to niobium-hafnium alloy parts produced with the PBF-LB additive manufacturing process for use in spaceflight, where high mechanical performance is required.
- Part Classification: Parts are classified into categories (A, B, C, D) based on criticality and intended use, with specifications for each category drawn from recognized spaceflight standards.
- Manufacturing Requirements:
- Use of pre-alloyed powder conforming to powder specification and control, with methods for blending and sieving to prevent contamination.
- Detailed process control for machine qualification, including key process variables and acceptance criteria.
- Personnel training according to ISO/ASTM and other relevant standards.
- Microstructure & Mechanical Properties:
- Requirements for density, grain size, and microstructural evenness for all part classes.
- Mechanical testing requirements per class, following accepted testing methods for tensile strength, yield strength, elongation, and area reduction.
- Inspection and Quality Assurance:
- Nondestructive examination protocols such as radiography and penetrant inspection, especially for critical part classes.
- Requirements for first article inspections, lot sampling, dimensional tolerance, surface finish, and rejection procedures.
- Documentation and Certification:
- Certificate of conformance required with shipment, stating compliance to the standard.
- Quality management system requirements (AS9100 or ISO 9001) for suppliers and powder vendors.
Applications
ASTM F3635-23 is primarily employed in the space industry, where the performance and reliability of components are paramount. The standard supports:
- Spaceflight hardware, such as propulsion system parts, nozzles, structural brackets, and thermal management components, benefiting from the high temperature and corrosion resistance of niobium-hafnium alloys.
- Aerospace additive manufacturing, allowing organizations to adopt PBF-LB for critical applications while ensuring consistent quality and traceability.
- Procurement specifications, where manufacturers and buyers must agree on detailed requirements for parts, from feedstock through post-processing and inspection.
- Qualification of new suppliers and processes, enabling systematic evaluation and onboarding of additive manufacturing within high-reliability sectors.
Related Standards
Several important standards are cross-referenced within ASTM F3635-23 to ensure comprehensive coverage of additive manufacturing quality and performance requirements:
- ISO/ASTM 52904: Practices for metal powder bed fusion to meet critical applications.
- NASA STD-6030: Additive Manufacturing Requirements for Spaceflight Systems.
- ISO/ASTM 52941 & 52942: System and operator qualification for aerospace.
- AS9100 / ISO 9001: Quality management systems for aviation, space, and defense.
- AMS2175: Casting classification and inspection for aerospace.
- E8/E8M, E112, E1742, E1417 (ASTM): Methods for mechanical testing, grain size, radiographic examination, and liquid penetrant inspection.
Summary
Adopting ASTM F3635-23 ensures that additively manufactured niobium-hafnium alloy parts for spaceflight meet stringent industry standards for performance, quality, and reliability. By referencing this standard, organizations benefit from a framework that aligns with global best practices in additive manufacturing and supports the delivery of high-quality, mission-critical components.
Keywords: additive manufacturing, niobium-hafnium alloy, powder bed fusion, PBF-LB, spaceflight, aerospace, ASTM F3635-23, UNS R04295, quality management, process qualification
Relations
- Effective Date
- 01-Jan-2024
- Effective Date
- 01-May-2022
- Effective Date
- 01-Apr-2022
Frequently Asked Questions
ASTM F3635-23 is a technical specification published by ASTM International. Its full title is "Standard Specification for Additive Manufacturing – Finished Part Properties – Standard Specification for Niobium-Hafnium Alloy UNS R04295 via Laser Beam Powder Bed Fusion for Spaceflight Applications". This standard covers: SCOPE 1.1 This specification covers additive manufacturing of parts manufactured via laser beam powder bed fusion (PBF-LB) processing of niobium-hafnium alloy used in spaceflight applications. Parts made using this processing method are typically used in applications that require mechanical properties like wrought products. Products built to this specification may require additional post-processing in the form of machining, polishing etc. to meet necessary surface finish and dimensional tolerances. 1.2 This specification is intended for the use of purchasers or producers, or both, of PBF-LB R04295 parts for defining the requirements based on classification methodology. These requirements shall be agreed upon by the part supplier and purchaser. 1.3 Users are advised to use this specification as a basis for obtaining parts that will meet the minimum acceptance requirements established and revised by consensus of committee members. 1.4 User requirements considered more stringent may be met by the addition to the purchase order. 1.5 Units—The values stated in SI units are to be regarded as the standard. Other units are included only for informational purposes. 1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use. 1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
SCOPE 1.1 This specification covers additive manufacturing of parts manufactured via laser beam powder bed fusion (PBF-LB) processing of niobium-hafnium alloy used in spaceflight applications. Parts made using this processing method are typically used in applications that require mechanical properties like wrought products. Products built to this specification may require additional post-processing in the form of machining, polishing etc. to meet necessary surface finish and dimensional tolerances. 1.2 This specification is intended for the use of purchasers or producers, or both, of PBF-LB R04295 parts for defining the requirements based on classification methodology. These requirements shall be agreed upon by the part supplier and purchaser. 1.3 Users are advised to use this specification as a basis for obtaining parts that will meet the minimum acceptance requirements established and revised by consensus of committee members. 1.4 User requirements considered more stringent may be met by the addition to the purchase order. 1.5 Units—The values stated in SI units are to be regarded as the standard. Other units are included only for informational purposes. 1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use. 1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
ASTM F3635-23 has the following relationships with other standards: It is inter standard links to ASTM E8/E8M-24, ASTM E8/E8M-22, ASTM F3122-14(2022). Understanding these relationships helps ensure you are using the most current and applicable version of the standard.
ASTM F3635-23 is available in PDF format for immediate download after purchase. The document can be added to your cart and obtained through the secure checkout process. Digital delivery ensures instant access to the complete standard document.
Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F3635 − 23
Standard Specification for
Additive Manufacturing – Finished Part Properties –
Standard Specification for Niobium-Hafnium Alloy UNS
R04295 via Laser Beam Powder Bed Fusion for Spaceflight
Applications
This standard is issued under the fixed designation F3635; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
1.1 This specification covers additive manufacturing of
Barriers to Trade (TBT) Committee.
parts manufactured via laser beam powder bed fusion (PBF-
LB) processing of niobium-hafnium alloy used in spaceflight
2. Referenced Documents
applications. Parts made using this processing method are
2.1 ASTM Standards:
typically used in applications that require mechanical proper-
D3951 Practice for Commercial Packaging
ties like wrought products. Products built to this specification
E3 Guide for Preparation of Metallographic Specimens
may require additional post-processing in the form of
E8/E8M Test Methods for Tension Testing of Metallic Ma-
machining, polishing etc. to meet necessary surface finish and
terials
dimensional tolerances.
E29 Practice for Using Significant Digits in Test Data to
1.2 This specification is intended for the use of purchasers
Determine Conformance with Specifications
or producers, or both, of PBF-LB R04295 parts for defining the
E112 Test Methods for Determining Average Grain Size
requirements based on classification methodology. These re-
E367 Test Methods for Chemical Analysis of Ferroniobium
quirements shall be agreed upon by the part supplier and
E407 Practice for Microetching Metals and Alloys
purchaser.
E1245 Practice for Determining the Inclusion or Second-
1.3 Users are advised to use this specification as a basis for Phase Constituent Content of Metals by Automatic Image
Analysis
obtaining parts that will meet the minimum acceptance require-
E1417 Practice for Liquid Penetrant Testing
ments established and revised by consensus of committee
members. E1447 Test Method for Determination of Hydrogen in Re-
active Metals and Reactive Metal Alloys by Inert Gas
1.4 User requirements considered more stringent may be
Fusion with Detection by Thermal Conductivity or Infra-
met by the addition to the purchase order.
red Spectrometry
1.5 Units—The values stated in SI units are to be regarded
E1479 Practice for Describing and Specifying Inductively
as the standard. Other units are included only for informational
Coupled Plasma Atomic Emission Spectrometers
purposes.
E1742 Practice for Radiographic Examination
1.6 This standard does not purport to address all of the E2234 Practice for Sampling a Stream of Product by Attri-
safety concerns, if any, associated with its use. It is the butes Indexed by AQL
responsibility of the user of this standard to establish appro- E2626 Guide for Spectrometric Analysis of Reactive and
priate safety, health, and environmental practices and deter- Refractory Metals (Withdrawn 2017)
mine the applicability of regulatory limitations prior to use. E2762 Practice for Sampling a Stream of Product by Vari-
1.7 This international standard was developed in accor- ables Indexed by AQL
dance with internationally recognized principles on standard- F2971 Practice for Reporting Data for Test Specimens Pre-
ization established in the Decision on Principles for the pared by Additive Manufacturing
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
This specification is under the jurisdiction of ASTM Committee F42 on contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Additive Manufacturing Technologies and is the direct responsibility of Subcom- Standards volume information, refer to the standard’s Document Summary page on
mittee F42.07 on Applications. the ASTM website.
Current edition approved Nov. 1, 2023. Published January 2024. DOI: 10.1520/ The last approved version of this historical standard is referenced on
F3635-23. www.astm.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3635 − 23
F3122 Guide for Evaluating Mechanical Properties of Metal 3.1.2 Part positioning and orientation related to coordinate
Materials Made via Additive Manufacturing Processes systems in ISO/ASTM 52921 shall apply.
2.2 ISO/ASTM Standards:
4. Classification
52900 Terminology for Additive Manufacturing — General
Principles — Terminology
4.1 All parts made to this specification shall be given a
52901 Guide for Additive Manufacturing — General Prin-
classification A, B, C, D, according to the NASA STD–6030.
ciples — Requirements for Purchased AM Parts
52904 Additive Manufacturing — Process Characteristics
5. Condition
and Performance — Practice for Metal Powder Bed
5.1 All conditions shall meet the requirements in each
Fusion Process to Meet Critical Applications
section of this standard.
52915 Specification for Additive Manufacturing File Format
5.1.1 Condition ANN parts shall be annealed. Anneal for 60
(AMF) Version 1.2
6 15 min at 1093 6 15°C.
52921 Terminology for Additive Manufacturing-Coordinate
5.1.2 Condition HIP parts shall be hot isostatically pressed.
Systems and Test Methodologies
Process components under inert atmosphere at not less than
52930 Additive manufacturing — Qualification principles
100 MPa within the range of 1575 to 1625°C; hold at the
— Installation, operation, and performance (IQ/OQ/PQ)
selected temperature within 615°C for 120 6 30 min and cool
of PBF-LB equipment
under inert atmosphere to below 425°C, or to parameters as
52941 Additive Manufacturing — System performance and
agreed upon between the component supplier and purchaser.
reliability — Acceptance Tests for laser metal powder bed
5.1.3 Condition OPT parts all thermal post processing shall
fusion machines for metallic materials for aerospace
be optional.
application
5.2 The purchaser may specify multiple conditions on the
52942 Additive Manufacturing — Qualification principles
purchase order such as Condition SR / HIP.
— Qualifying machine operators of metal laser powder
5.2.1 Class A, B, C parts shall be delivered in the ANN
bed fusion machines and equipment used in aerospace
condition.
applications
4 5.2.2 Class A parts shall be processed by Hot Isostatic
2.3 ISO Standards:
Pressing (HIP) and HIP shall be optional for all other classi-
ISO 9001 Quality management system — Requirements
fications.
ISO 9044 Industrial woven wire cloth — Technical require-
5.2.3 Class D parts (As described in NASA STD–6030
ments and testing
Table 22) shall be delivered in condition as agreed upon
ISO 9712 Non-destructive testing — Qualification and cer-
between supplier and purchaser.
tification of NDT personnel
2.4 SAE Standards:
NOTE 1—HIP can introduce significant contamination risk to UNS
R04295 alloy due to other parts outgassing in coach HIP cycles. Nadcap
AMS2175 Castings, Classification, and Inspection of
accreditation is recommended for HIP vendors.
AS9100 Quality Management Systems — Requirements for
Aviation, Space and Defense Organizations
6. Ordering Information
2.5 ASME Standard:
6.1 Parts shall be ordered in accordance with ISO/ASTM
ASME B46.1 Surface Texture (Roughness, Waviness, Lay)
52901 and include the specified condition(s) and classification
2.6 NASA Standard:
per this specification.
NASA STD–6030 Additive Manufacturing Requirements
for Spaceflight Systems 6.2 Supplementary requirements shall be stated on the
2.7 National Aerospace Standard: purchase order.
NAS410 National Aerospace Standard Certification &
7. Manufacturing Plan
Qualification of Non-destructive Test Personnel
2.8 ANSI / ASNT Standard:
7.1 All classification of parts manufactured to this specifi-
CP189 ASTN Standard for Qualification and Certification of
cation shall have a manufacturing plan in accordance with
Nondestructive Testing Personnel
Practice ISO/ASTM 52904.
3. Terminology
8. Feedstock and Powder Batches
3.1 Definitions:
8.1 Classifications A, B, C of parts manufactured to this
3.1.1 Terminology relating to additive manufacturing in
specification shall use pre-alloyed powder and control powder
Terminology ISO/ASTM 52900 shall apply.
batches in accordance with Practice ISO/ASTM 52904.
8.1.1 The part manufacturer shall flow-down powder speci-
4 fications to their powder vendor and have receiving procedures
Available from American National Standards Institute (ANSI), 25 W. 43rd St.,
that ensure the powder meets the requirements in ISO/ASTM
4th Floor, New York, NY 10036, http://www.ansi.org.
Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,
52904.
PA 15096, http://www.sae.org.
8.1.2 Virgin and used powder may be blended to produce
Available from American Society of Mechanical Engineers (ASME), ASME
parts for all classifications. Used powder shall meet the
International Headquarters, Two Park Ave., New York, NY 10016-5990, http://
www.asme.org. requirements of Practice ISO/ASTM 52904.
F3635 − 23
8.1.3 For Class A and B part production, the process for 11. Process (Class A, B, C)
sieving used feedstock shall maintain the powder specification
11.1 Process shall be agreed upon by the part supplier and
in 8.1.1.
purchaser.
8.1.4 For Class A and B part production, the supplier shall
11.2 All classifications of parts manufactured to this speci-
provide objective evidence that changing the alloy type in the
fication shall meet the requirements of ISO/ASTM 52904 for:
PBF-LB machine does not cause part contamination.
11.2.1 Control of machine operating system software.
8.1.5 Blending of powder lots is permitted. Powder blends
11.2.2 Digital data configuration control.
with more than 2 powder lots, shall require powder sample
11.2.3 External (to the PBF-LB process) environment con-
capsules to be processed in the build cycles. The number and
trol.
location of powder capsules shall be determined by part
manufacturer. The powder in the capsules shall meet the
11.3 Permissible parameter or process changes and extent of
requirements in this section. external intervention during the build cycle shall be identified
in the manufacturing plan.
NOTE 2—Examples of capsules sizes can be found in the document link
11.3.1 Parameter or process changes requires a new first
here. NIST Advanced Manufacturing Series 100-17.
article inspection (FAI) for Class A and B.
9. Machine Qualification (Class A, B, C)
11.3.2 All process changes shall be monitored and recorded.
When agreed to by the purchaser, minor changes to the
9.1 All machines producing parts shall be within acceptance
manufacturing plan may be made without re-qualification, for
limits defined in ISO/ASTM 52941.
example, change of operation sequences.
9.2 Key process variables shall be determined in accordance
11.4 Post processing operations may be used to achieve the
with ISO/ASTM 52930.
desired shape, size, surface finish or other part properties.
9.3 When the process can meet the microstructure density
requirements in Section 13, the process shall be fixed with no
12. Chemical Composition Evaluation
additional changes to key process variables under process
controls in ISO/ASTM 52904. 12.1 As delivered (except for coatings) chemical composi-
tion of parts shall conform to the requirements specified in
9.4 Initial machine and material qualification shall consist
Table 1. Methods and practices relating to as built chemical
of three builds each with a minimum of 16 tension test
analysis required by this specification shall be in accordance
specimens and 4 density test specimens. Test specimen orien-
with Practice E1479, Test Methods E367, or a combination
tation shall be 12 in Z direction, 2 in X direction, and 2 in Y
thereof, as appropriate. Hydrogen shall be measured in accor-
direction located within the XY build envelope intended for
dance with Test Method E1447. Other analytical methods may
part production.
be used if agreed upon by the part supplier and purchaser.
9.4.1 Tension test specimens shall meet the requirements in
12.1.1 Analysis for elements not listed in Table 1 is not
Section 14 after machining to Test Method E8/E8M dimen-
required to certify compliance with this specification.
sions.
12.1.2 Alternative analytical methods may be used if agreed
9.4.2 Density test specimens shall meet the requirements in
upon by the part supplier and purchaser (refer to Guide E2626).
Section 13 when processed with only hatch scanning.
9.4.3 Chemical composition shall meet the requirements in 12.2 Chemical check (product) analysis limits shall be as
Section 12. shown in Table 2. Chemical check analysis tolerances do not
broaden the requirements in Table 1 for the powder or part
9.5 Upon successful completion of 9.4, the machine shall be
supplier but cover variations between laboratories in the
considered qualified. Changes to the key process variables
measurement of chemical content. The part supplier shall not
require re-qualification in accordance with Section 9.
certify parts to this s
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