The present and future of additive manufacturing in the aerospace sector: A review of important aspects

Uriondo, Adrián; Esperon-Miguez, Manuel; Perinpanayagam, Suresh

doi:10.1177/0954410014568797

Cited by 379 publications

(176 citation statements)

References 64 publications

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“…Therefore, post-processing treating is required to the purpose of surface modification [6,7]. Among a wide range of possible applications of AM, interest is currently devoted to superalloys for aerospace, automotive, and chemical industry [8], where outstanding combination of mechanical properties and wear resistance is required. In this frame, Inconel 718 (IN718), a solid-solution or precipitation strengthened Ni-based austenite superalloy [9], is receiving increasing interest, as being widely used to produce exhaust pipes, parts for rocket motors, gas turbines, and nuclear reactors.…”

Section: Introductionmentioning

confidence: 99%

Laser powder-bed fusion of Inconel 718 to manufacture turbine blades

Caiazzo

Alfieri

Corrado

et al. 2017

Int J Adv Manuf Technol

112

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In the frame of additive manufacturing of metals, laser powder-bed fusion is investigated in this paper as an advanced industrial prototyping tool to manufacture Inconel 718 turbine blades at a predesign stage before flow production. Expediting of the evaluation of any upgrade to the part is aimed. To this purpose, possible anisotropy of manufacturing is preliminarily investigated via tensile testing at room and elevated temperature as a function of the sloping angle with the building plate; the normalized strength is given and compared with similar studies in the literature. Positioning and proper supporting in manufacturing are discussed; the parts are further investigated to assess their compliance with the intended nominal geometry.

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Section: Introductionmentioning

confidence: 99%

Laser powder-bed fusion of Inconel 718 to manufacture turbine blades

Caiazzo

Alfieri

Corrado

et al. 2017

Int J Adv Manuf Technol

112

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“…All these features lead to an increased local stress concentration which promotes fatigue crack initiation. Moreover, the fatigue behaviour of AM materials with rough as-built surfaces is dominated by the surface roughness rather than by internal defects [18].…”

Section: Fatiguementioning

confidence: 99%

“…Moreover, reduced machining by producing AM parts with final or near-net-shape geometry would considerably reduce the amount of machining which is an expensive for tough materials, like for example titanium and nickel base alloys [4]. There are however still a number of challenges yet to be solved before AM can be fully utilized in aerospace applications, a few of them are listed below [18]:…”

Section: Am For Aerospace Applicationsmentioning

confidence: 99%

Fatigue Performance of Additive Manufactured Ti6Al4V in Aerospace Applications

Kahlin¹

2017

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Additive Manufacturing (AM) for metals includes is a group of production methodst hat use a layer-by-layer approach to directly manufacture final parts. In recent years, the production rate and material quality of additive manufactured materials have improved rapidly which has gained increased interest from the industry to use AM not only for prototyping, but for serial production. AM offers a greater design freedom, compared to conventional production methods, which allows for parts with new innovative design. This is very attractive to the aerospace industry, in which parts could be designed to have reduced weight and improved performance contributing to reduced fuel consumption, increased payload and extended flight range. There are, however, challenges yet to solve before the potential of AM could be fully utilized in aerospace applications. One of the major challenges is how to deal with the poor fatigue behaviour of AM material with rough as-built surface. The aim of this thesis is to increase the knowledge of how AM can be used for high performance industrial parts by investigating the fatigue behaviour of the titanium alloy Ti6Al4V produced with different AM processes. Foremost, the intention is to improve the understanding of how rough as-built AM surfaces in combination with AM built geometrical notches affects the fatigue properties.This was done by performing constant amplitude fatigue testing to compare different combinations of AM material produced by Electron Beam Melting(EBM) and Laser Sintering (LS) with machined or rough as-built surfaces with or without geometrical notches and Hot Isostatic Pressing (HIP) treatment. Furthermore, the material response can be different between constant amplitude and variable amplitude fatigue loading due to effects of overloads and local plastic deformations. The results from constant amplitude testing were used to predict the fatigue life for variable amplitude loading by cumulative damage approach and these predictions were then verified by experimental variable amplitude testing. The constant amplitude fatigue strength of material with rough as-built surfaces was found to be 65-75 % lower, compared to conventional wrought bar, in which HIP treatments had neglectable influence on the fatigue strength. Furthermore, the fatigue life predictions with cumulative damage calculations showed good agreement with the experimental results which indicates that a cumulative damage approach can be used, at least for a tensile dominated load sequences, to predict the fatigue behaviour of additive manufactured Ti6Al4V

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“…It is currently difficult from part to part and on different occasions to produce identical parts. With the current challenges of AM, a current goal is to better understand the thermal cycles and complex microstructural formation of AMED parts (Uriondo et al, 2015).…”

Section: Relevance and Significancementioning

confidence: 99%

“… Quick production time (Nakano et al, 2015)  Reduced number of production steps, near net shape process (Zietala et al, 2016)(Nakono et al, 2015  No tooling needed, reducing time and cost (Holmström, 2010)  Customisation (Holmström, 2010)  Ability to easily make changes to design (Holmström, 2010)  Production of complex parts (Uriondo et al, 2015)  Can produce parts with complex internal structures (Nakano et al, 2015)  Ability to produce both solid and porous structures (Li et al, 2010)  Repair of parts (Uriondo et al, 2015)  Small production batches are feasible and economical (Holmström, 2010)  Reduction of waste (Holmström, 2010)  A high percentage of the material can be recycled (Nakano et al, 2015)  New design possibilities, including multi-material parts (Shapiro et al, 2016) These benefits of AM drive the interest in research and development of AM technologies.…”

Section: Benefits Of Ammentioning

confidence: 99%

Investigation into the effect of subsequent layer addition on the microstructure and properties of previous layers during direct laser deposition of 316L stainless steel

Robinson¹

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Additive manufacturing (AM) is a new and emerging technology in which further research is needed in order to make the most of its potential and unique benefits compared to conventional manufacturing. This current work helps to develop an understanding of AM processes by investigating the effect of subsequent layer addition on previous layers during direct laser deposition. As subsequent layers are added to a part, heat is transferred into previous layers, which may change the microstructure and properties of the pervious layers.There is no current research into the effect of these reheating cycles. In this work a new and innovative approach is used in which samples of different numbers of layers are produced and analysed, allowing the effect of reheating due to subsequent layer addition to be individually investigated. A LENS 450 system is used to produce samples of various numbers of layers (2 layer, 3 layer, 4 layer etc.) and the microstructure and hardness of the same layer in different samples is compared. Before the main research was performed the processing parameters were optimised for the LENS 450 system. It was determined that a powder feed rate of 5rpm, scanning speed of 18ipm and laser power of 300W produced the best component for this system, with a minimum amount of porosity. The optimum sample had only 0.34% porosity and a hardness of 203HV ± 23HV. The overall outcome of the work was that a generation of new knowledge about direct laser deposition processes was obtained, which will thus help in future development and control of AM processes. It was concluded that there was no significant change in properties with the subsequent layer addition due to the austenitic stainless steel exhibiting no phase changes on heating or cooling, which is a property unique to the austenitic stainless steels. END ii Acknowledgement

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The present and future of additive manufacturing in the aerospace sector: A review of important aspects

Cited by 379 publications

References 64 publications

Laser powder-bed fusion of Inconel 718 to manufacture turbine blades

Laser powder-bed fusion of Inconel 718 to manufacture turbine blades

Fatigue Performance of Additive Manufactured Ti6Al4V in Aerospace Applications

Investigation into the effect of subsequent layer addition on the microstructure and properties of previous layers during direct laser deposition of 316L stainless steel

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