Lightweight design of an AlSi10Mg aviation control stick additively manufactured by laser powder bed fusion

Wang, Di; Wei, Xiongmian; Liu, Jian; Xiao, Yunmian; Yang, Yongqiang; Liu, Linqing; Tan, Chaolin; Yang, Xusheng; Han, Changjun

doi:10.1108/rpj-02-2022-0064

Cited by 12 publications

(7 citation statements)

References 29 publications

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“…In the case of high energy input, distortions and irregularities will appear because of big melt pool volumes and recoil pressure aspects. It was found that the stability of the melt pool is a significant factor in producing high-density components (Kempen et al , 2012; Kempen et al , 2015; Wang et al , 2022).…”

Section: Characteristics Of Produced Componentsmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

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Purpose The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed. Design methodology approach Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes. Findings The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants. Originality value This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

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Section: Characteristics Of Produced Componentsmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

View full text Add to dashboard Cite

show abstract

“…Furthermore, in respect of metal manufacturing, PBF is increasingly being employed due to its high degree of fabrication freedom without the use of other part-specific supplies, short design and fabrication periods, and the revolution of conventional manufacturing technologies in realizing an immense amount of time saved and low commercial costs [6][7][8]. In short, not only does PBF manufacturing not require extra devices, but it is also not restricted by complex part geometry, giving rise to multitudinous advantages, such as speediness, a short production period, and low cost [9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Effect of Annealing and Hot Isostatic Pressing on the Structure and Hydrogen Embrittlement Resistance of Powder-Bed Fusion-Printed CoCrFeNiMn High-Entropy Alloys

Feng

He³

et al. 2023

Metals

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As an additive-manufacturing (AM) technique, powder-bed fusion (PBF) shows tremendous potential in both the research and industrial communities. Research on the post-treatment of PBF-prepared products is a hot topic. Hydrogen embrittlement (HE) resistance is a practical necessity, especially in microstructures. Here, the effect of annealing and hot isostatic pressing (HIP) on the properties of PBF technology-printed CoCrFeNiMn high-entropy alloys (HEAs) is investigated. The results show that these two post-thermal treatment approaches can release residual stress (from approximately 338 to 44 MPa) from PBF-printed samples, which is the main reason for declines in hardness (from approximately 211 to 194 HV). In addition, both annealing and HIP can reduce HE sensitivity, thus improving resistance to HE, with elongation increasing by 75.4% and 85.4% after annealing and HIP, respectively. In summary, both post-thermal treatments are of great significance to the development of HEAs with optimized structures and protection against HE, which can contribute to the development of these behaviors during application.

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“…The optimization results were used as the basis for size optimization to determine the optimal combination of structural parameters and further realize the lightweight design of temporary rectangular shield support device. 16,17 According to different roadway handling and disassembly requirements, the modular lightweight matching research is carried out for modules with large volume and mass ratios, and optimal matching scheme is determined. Finally, the finite element software was used to simulate and analyze the key modules to verify the reliability of the lightweight design.…”

Section: Introductionmentioning

confidence: 99%

Lightweight design of temporary support device of rectangular shield for the robot system of coal mine roadway excavation

Wang

et al. 2023

Advances in Mechanical Engineering

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Owing to the existing problems of the temporary shield support device in a coal mine, such as considerable component weight, difficult disassembly, and large chamber installation, the design of the temporary rectangular shield support device was optimized. A module division method combining the functional analysis method and a similar feature clustering method was proposed, which completes the division of the functional module and establishes the structural module. A structural optimization method of “variable density topology optimization, parameter sensitivity analysis and Optimal Space-Filling Design (OSF)” was proposed. A variable-density topology optimization model of the device was established using the variable-density topology optimization method. The key variables of the device were determined using a parameter sensitivity analysis. The sample points of the critical variables were generated using the optimal space-filling design method, the approximate response surface models of mass, displacement, and stress were constructed, and the optimal solution of the device’s weight was obtained under the constraint conditions of pressure and displacement. A lightweight matching method of modularization based on transportability, disassembly, maintainability, and reliability was proposed, and the optimal matching scheme for the volume and mass of the device was determined. As a result, the weight of the temporary shield support device was reduced by 11.2%, and the maximum stress was reduced by 13.4%, under the premise of ensuring reliability. It realizes the convenience of transportation and high efficiency of assembly and disassembly in different design requirements, which is of great significance to accelerate the intelligent construction of coal mine.

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Lightweight design of an AlSi10Mg aviation control stick additively manufactured by laser powder bed fusion

Cited by 12 publications

References 29 publications

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Effect of Annealing and Hot Isostatic Pressing on the Structure and Hydrogen Embrittlement Resistance of Powder-Bed Fusion-Printed CoCrFeNiMn High-Entropy Alloys

Lightweight design of temporary support device of rectangular shield for the robot system of coal mine roadway excavation

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