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

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

doi:10.1504/ijrapidm.2020.107736

Cited by 44 publications

(13 citation statements)

References 30 publications

(60 reference statements)

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“…The contribution of additive manufacturing in the manufacturing sector has attracted a bit more attention in recent times as compared to conventional manufacturing [38]. The main reason for this is many advantages such as lightweight, low material wastage of material, low cost, less lead time, low emission, and facilities that can easily produce hard material [39]. As proof of this, the use of additive manufacturing in forming, castings, etc.…”

Section: Doe (Design Of Experimentsmentioning

confidence: 99%

Challenges and Opportunities in Additive Manufacturing Polymer Technology: A Review Based on Optimization Perspective

Raja

Rajan

2023

Advances in Polymer Technology

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In the emerging modern technology of additive manufacturing, the need for optimization can be found in literature in many places. Additive manufacturing (AM) is making an object layer by layer directly from digital data. Previous works of literature have classified additive manufacturing processes into seven types. However, there is a lack of comprehensive review describing the optimization challenges and opportunities in the material extrusion process (polymer technology) and also the need for FDM polymer materials application in impeller making. In this review paper, a specific optimization method called multicriteria decision-making (MCDM) from the mathematical programming technique used in additive manufacturing polymer technology (AMPT) is discussed. The other topics such as different types of optimization techniques, applications of different MCDM tools and their applications in different fields including AM, and the optimization challenges and opportunities in AMPT particularly impeller application are discussed.

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Section: Doe (Design Of Experimentsmentioning

confidence: 99%

Challenges and Opportunities in Additive Manufacturing Polymer Technology: A Review Based on Optimization Perspective

Raja

Rajan

2023

Advances in Polymer Technology

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“…DED is primarily used in the construction of large scale parts [19][20][21][22] or the repair and reclamation of Ni-based superalloy components [15,23,24]. It does not offer the same part resolution as PBF and, therefore, is rarely used in the construction of smaller individual engineered parts [25,26]. DED processes offer opportunities for fabricating parts with volumes of a couple cm 3 to over a m 3 , resulting sometimes in large variations in the mechanical and microstructural properties [22].…”

Section: Scope Of This Reviewmentioning

confidence: 99%

Powder bed fusion additive manufacturing of Ni-based superalloys: a review of the main microstructural constituents and characterization techniques

et al. 2022

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Metal additive manufacturing (AM) has unlocked unique opportunities for making complex Ni-based superalloy parts with reduced material waste, development costs, and production lead times. Considering the available AM methods, powder bed fusion (PBF) processes, using either laser or electron beams as high energy sources, have the potential to print complex geometries with a high level of microstructural control. PBF is highly suited for the development of next generation components for the defense, aerospace, and automotive industries. A better understanding of the as-built microstructure evolution during PBF of Ni-based superalloys is important to both industry and academia because of its impacts on mechanical, corrosion, and other technological properties, and, because it determines post-processing heat treatment requirements. The primary focus of this review is to outline the individual phase formations and morphologies in Ni-based superalloys, and their correlation to PBF printing parameters. Given the hierarchal nature of the microstructures formed during PBF, detailed descriptions of the evolution of each microstructural constituent are required to enable microstructure control. Ni-based superalloys microstructures commonly include γ, γ′, γ′′, $$\delta$$ δ , TCP, carbides, nitrides, oxides, and borides, dependent on their composition. A thorough characterization of these phases remains challenging due to the multi-scale microstructural hierarchy alongside with experimental challenges related to imaging secondary phases that are often nanoscale and (semi)-coherent. Hence, a detailed discussion of advanced characterization techniques is the second focus of this review, to enable a more complete understanding of the microstructural evolution in Ni-based superalloys printed using PBF. This is with an expressed goal of directing the research community toward the tools necessary for a thorough investigation of the processing-microstructure-property relationships in PBF Ni-based superalloy parts to enable microstructural engineering.

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“…For the component under study, a proper AM technology is the L-PBF, which is well suited for creating small and medium batches of metal components with complex shape, and limited size [48]. Moreover, the L-PBF technique is suitable for manufacturing components that have a proper balance between the minimum producible detail level and a good surface nishing [49]. This process involves using a laser to selectively melt metal powders.…”

Section: Am Production Feasibilitymentioning

confidence: 99%

Exploiting the generative design potential to select the best conceptual design of an aerospace component to be produced by additive manufacturing

Pilagatti

Atzeni²,

Salmi³

2022

Preprint

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Since the advent of Industry 4.0, the manufacturing sector has had to face new challenges, which have required the development of new skills and innovative tools. This scenario includes innovative production processes such as Additive Manufacturing (AM), a technology capable of producing a component layer-by-layer directly from the 3D model, without the need of specific tools. Generative Design (GD) may represent an opportunity to maximize the potential of AM techniques. GD is based on parametric computer-aided design (CAD) tools capable of generating multiple optimized outputs, among which the designer could select the most promising solution. This paper presents a general methodology for evaluating the GD outputs in the conceptual phase of design, to select the best possible solution through a series of criteria at several levels. The evaluation method is deployed in an aerospace field case study. The procedure demonstrates the benefits of adopting GD synergistically with AM in the early stages of product development. This indicates that the developed methodology could reduce the number of iterations during the design process, and the result is a decrease in the overall time spent on the project, avoiding problems during the final stages of the design.

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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 44 publications

References 30 publications

Challenges and Opportunities in Additive Manufacturing Polymer Technology: A Review Based on Optimization Perspective

Challenges and Opportunities in Additive Manufacturing Polymer Technology: A Review Based on Optimization Perspective

Powder bed fusion additive manufacturing of Ni-based superalloys: a review of the main microstructural constituents and characterization techniques

Exploiting the generative design potential to select the best conceptual design of an aerospace component to be produced by additive manufacturing

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