A comparison framework to support the selection of the best additive manufacturing process for specific aerospace applications

Garcia-Colomo, Alberto; Wood, Dudley; Martina, Filomeno; Williams, Stewart

doi:10.1504/ijrapidm.2020.10019230

Cited by 10 publications

(2 citation statements)

References 40 publications

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“…As mentioned before, Powder Bed Fusion technology is constrained by its printing area, limiting the possibilities of this technology. Furthermore, its low feeding rate makes this technology the least optimal to achieve BAAM constructions [57]. Within the second selected criteria, energy consumption was considered regardless of its final geometry complexity [58].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Marqués,

Dieste,

Monzón

et al. 2024

Materials

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Additive manufacturing (AM) has been fully incorporated into both the academic and the industrial world. This technology has been shown to lower costs and environmental impacts. Moreover, AM-based technologies, such as wire arc additive manufacturing (WAAM), have been proven suitable for the manufacturing of large products with significant mechanical requirements. This study examines the manufacture of two aeronautical toolings: first, using conventional techniques, and second, using a big area additive manufacturing (BAAM) process, specifically WAAM technology, followed by second-stage hybrid machining. Both toolings can be considered interchangeable in terms of design and performance. Energy and material consumption were analysed and compared throughout both tooling procedures. The results show the important optimisation of both procedures in manufacturing WAAM tooling, encompassing the additive process and second-stage hybrid machining. Nevertheless, the time required for WAAM tooling manufacturing increased significantly compared to conventional manufacturing tooling. Moreover, based on metrology data from the AM process, a theoretical study was conducted to assess different design optimisations for WAAM tooling manufacturing and determine their influence on material and energy consumption. These theoretical results improve those already obtained regarding energy and raw material savings.

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Section: Introductionmentioning

confidence: 99%

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Marqués,

Dieste,

Monzón

et al. 2024

Materials

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show abstract

“…At each incremental step, the raw material is selectively melted by the energy source, a laser in L-PBF or an electron beam in EBM. EBM and L-PBF processes are anyway not competing; rather they offer different advantages for different types of applications [8]. EBM and L-PBF parts of identical material are characterized by significantly different microstructures and mechanical properties, and the surface topology and quality are also distinctive [9,10].…”

Section: Introductionmentioning

confidence: 99%

Abrasive fluidized bed finishing to improve the fatigue behaviour of Ti6Al4V parts fabricated by electron beam melting

Atzeni

Rubino

Salmi

et al. 2020

Int J Adv Manuf Technol

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A study of the abrasive fluidized bed (AFB) finishing process was conducted to quantify the obtainable improvement of the fatigue behaviour of Ti6Al4V parts produced by electron beam melting (EBM). Axial-symmetric EBM samples were rotated at high speed inside a fluidized bed of stainless-steel media. The effects of the treatment time and the rotational speed on morphological features and fatigue life of the EBM samples were investigated. Outcomes showed that the improvement in surface properties induced by the AFB finishing process determined an increase up to 50% in fatigue life and a shift of the S-N curve.

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Understanding the Effects of Manufacturing Attributes on Damage Tolerance of Additively Manufactured Parts and Exploring Synergy Among Process‐Structure‐Properties. A Comprehensive Review

Uddin,

Butt,

Kvvssn

et al. 2024

Engineering Reports

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Additive Manufacturing (AM) has revolutionized the production industry by offering design freedom with shorter lead times and reduced material wastage. However, the damage tolerance (DT) of AM parts is a significant concern due to their microstructural and geometric complexities, which affect their mechanical performance. This article aims to provide a comprehensive overview of the manufacturing parameters affecting the components produced by AM specifically selective laser melting (SLM). Detailed discussions are presented on the effects of manufacturing attributes on the microstructure, defects, and mechanical characteristics of AM parts. Depending on these aspects, basic concepts are studied and critically explained specifically for AM materials. The basic criterion for damage‐tolerant component design, the criterion for fatigue and fracture properties, and the effect of the defects on fatigue life are critically presented. In addition, the effect of different types of gradation on the crack growth behavior of samples processed by SLM is also investigated in depth. There is currently a lack of a specific review study in the literature that establishes a connection between process attributes and metallographic properties, and their impact on the damage behavior of additively manufactured parts. This gap in research highlights the need for a comprehensive review to bridge this knowledge deficit and provide valuable insights for understanding the relationships between manufacturing processes, material characteristics, and the structural integrity of additively manufactured components. This review concludes by addressing the challenges and opportunities in designing and qualifying AM parts for damage tolerance.

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A comparison framework to support the selection of the best additive manufacturing process for specific aerospace applications

Abstract: Buy-to-fly is the ratio between the quantity of the starting raw material and that left in the finished component.

Cited by 10 publications

References 40 publications

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Abrasive fluidized bed finishing to improve the fatigue behaviour of Ti6Al4V parts fabricated by electron beam melting

Understanding the Effects of Manufacturing Attributes on Damage Tolerance of Additively Manufactured Parts and Exploring Synergy Among Process‐Structure‐Properties. A Comprehensive Review

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