Manufacturing of aircraft engine transmission gear with SLS (DMLS) method

Abstract

Purpose The purpose of this paper is to present the methodology for manufacturing of aircraft transmission gears using incremental method of rapid prototyping (RP) – direct metal laser sintering (DMLS). The production of prototypes from metallic powders using described system allows the execution of final elements of complex structures with additional economic impacts. Design/methodology/approach The paper describes the use of selective laser sintering method (DMLS) by EOS Company. Whole chain of production of prototype is presented with the addition of geometric accuracy measurements by blue light laser device. Findings Presented in the research analysis of SLS/SLM technologies as rapid manufacturing systems shows that they can be applied in the production of prototypes used in the manufacturing process of gears for propulsion systems in aviation industry. Also, very important is the geometrical accuracy of gear prototypes produced by incremental methods. It determines subsequent treatment steps for aircraft propulsion system gears. Practical Implications The use of RP techniques as an alternative for conventionally used manufacturing method has mainly an economic impact related to the cost of time-consuming process and amount of defected elements appearing in serial production. Originality/value This paper presents possibility to use RP – DMLS system – for propulsion elements of aircraft structure. This research is original because of the complex description of the whole chain of manufacturing process. Additionally, geometrical accuracy measurement methodology by blue light presented with the RP method of manufacturing gives the research a unique characteristic.

Effect of Process Parameter Modification and Hot Isostatic Pressing on the Mechanical Properties of Selectively Laser-Melted 316L Steel

“…The powder (LPW Technology) used for the production of all specimens was gas-atomized 316L steel produced in an argon atmosphere. Based on the scanning electron microscope (SEM) results, shown in Figure 1, powder particles were spherical with a diameter of 15 -63 µ m. The density of the material was 7.92 g/cm 3 and its flowability was 14.6 s/50 g.…”

“…Research on additive manufacturing with metal powders [1] has grown significantly, yet many research questions remain. The intensity of the research is driven by the wide use of additive manufacturing to make geometrically complex parts in fields such as medical devices [2], aviation [3], astronautics, and the automotive industry [4,5] and other mechanical solutions [6].…”

The potential of SLM technology for processing magnesium alloys in aerospace industry

“…Additive manufacturing (AM) technologies that are used to manufacture parts of both plastics and metals are one example of the technologies that have been developed since the 1980s. Presently, AM technologies are increasingly applied for the manufacture of ready-made parts both as indirect [2] and direct [3] technologies. Despite the significant progress that has been made in the field and a wide range of potential applications, they are not commonly used in the industry.…”

“…Magnesium and magnesium alloys are one of the lightest metallic materials. Their low density of 1.73 g/cm 3 and the resulting high specific strength make them a perfect alternative to slightly heavier aluminium alloys. The use of light alloys in aviation will result in reduced aircraft weight, which in turn means reduced fuel consumption as well as combustion product emission to the atmosphere.…”

Influence of Selective Laser Melting Technological Parameters on the Mechanical Properties of Additively Manufactured Elements Using 316L Austenitic Steel

“…Depending on the adopted process parameters, different material properties can be achieved without any additional post-processing treatment. Furthermore, it is possible to ensure a high geometric accuracy by minimizing the influence of thermal shrinkage effects [37]. These features will have a significant influence on the further development of the additive manufacturing technique and require additional studies.…”