Topological optimization and manufacturing by Direct Metal Laser Sintering of an aeronautical part in 15-5PH stainless steel

López-Castro, Juan de Dios; Marchal, Alexandre; González, Liliana; Botana, J.

doi:10.1016/j.promfg.2017.09.121

Cited by 24 publications

(5 citation statements)

References 2 publications

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“…With the development of aerospace and aircraft components, some structural parts of ultra‐high‐strength steel are becoming increasingly complex, and it is difficult to produce high‐precision complex structural parts using traditional methods . Therefore, it is necessary to manufacture complex structural parts using 3D printing technology to study the relationship between manufacturing defects and the properties of selective laser‐melted 15‐5PH ultra‐high‐strength stainless steel …”

Section: Introductionmentioning

confidence: 99%

Effect of Manufacturing Parameters on the Mechanical and Corrosion Behavior of Selective Laser‐Melted 15‐5PH Stainless Steel

Wang

Dong

Kong

et al. 2019

steel research int.

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The effect of manufacturing parameters on mechanical and corrosion resistance is investigated using tensile tests and electrochemical experiments for selective laser-melted 15-5PH stainless steel. The results demonstrate that when laser power is decreased to 150 W and scanning speed increased to 1400 mm s À1 , manufacturing defects increase. Plasticity and corrosion resistance reduce significantly. Cracks mainly originate from manufacturing defects and extend along the interface between molten pools. Corrosion occurs near manufacturing defects. Finally, the most suitable laser energy density is 130 J mm À3 for 15-5PH stainless steel.

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Section: Introductionmentioning

confidence: 99%

Effect of Manufacturing Parameters on the Mechanical and Corrosion Behavior of Selective Laser‐Melted 15‐5PH Stainless Steel

Wang

Dong

Kong

et al. 2019

steel research int.

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“…The design and non-design space of seat leg was defined as shown in Figure 6 based on aircraft seat designs in literature (Guida et al, 2018;Roper et al, 2021) and US Patents (Kismarton and Fullerton, 2013;Stachel et al, 2020). The material used for the design and non-design space was titanium, with generic material properties as follows: r is 4.50 g/cm 3 ; Poisson's ratio is 0.32; and Young's modulus is 110 GPa.…”

Section: Conceptual Design Phasementioning

confidence: 99%

Design of a metal additive manufactured aircraft seat leg using topology optimization and part decomposition

Kim,

Crispo,

Patel

et al. 2024

RPJ

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Purpose The lightweight design of aircraft seats can significantly improve fuel efficiency and reduce greenhouse gas emissions. Metal additive manufacturing (MAM) can produce lightweight topology-optimized designs with improved performance, but limited build volume restricts the printing of large components. The purpose of this paper is to design a lightweight aircraft seat leg structure using topology optimization (TO) and MAM with build volume restrictions, while satisfying structural airworthiness certification requirements. Design/methodology/approach TO was used to determine a lightweight conceptual design for the seat leg structure. The conceptual design was decomposed to meet the machine build volume, a detailed CAD assembly was designed and print orientation was selected for each component. Static and dynamic verification was performed, the design was updated to meet the structural requirements and a prototype was manufactured. Findings The final topology-optimized seat leg structure was decomposed into three parts, yielding a 57% reduction in the number of parts compared to a reference design. In addition, the design achieved an 8.5% mass reduction while satisfying structural requirements for airworthiness certification. Originality/value To the best of the authors’ knowledge, this study is the first paper to design an aircraft seat leg structure manufactured with MAM using a rigorous TO approach. The resultant design reduces mass and part count compared to a reference design and is verified with respect to real-world aircraft certification requirements.

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“…c A380 fuel connector [31]. d, e Topology optimized aerospace brackets [32,33] However, the LPBF technology has some limitations, too. Surface roughness of produced parts is a major issue for the broader use of this layer-by-layer process that leads to the widely known "staircase effect", particularly visible on sloping edges.…”

Section: Laser-based Powder Bed Fusionmentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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Topological optimization and manufacturing by Direct Metal Laser Sintering of an aeronautical part in 15-5PH stainless steel

Cited by 24 publications

References 2 publications

Effect of Manufacturing Parameters on the Mechanical and Corrosion Behavior of Selective Laser‐Melted 15‐5PH Stainless Steel

Effect of Manufacturing Parameters on the Mechanical and Corrosion Behavior of Selective Laser‐Melted 15‐5PH Stainless Steel

Design of a metal additive manufactured aircraft seat leg using topology optimization and part decomposition

Powder-based laser hybrid additive manufacturing of metals: a review

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