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Although its importance has increased significantly, Additive Manufacturing is not yet a fully accepted industrial manufacturing process for load-carrying parts. The future success of the process group depends on its standardization. This work proposes a methodology for the design, manufacturing, and quality evaluation of specimens manufactured by Fused Layer Modeling that are composed of only one layer (so-called monolayers). The processing methodology and properties of monolayers have not been studied systematically yet. A first systematic design of monolayers for mechanical testing is presented. Rectangular and circular monolayers adapted to the loads of tensile and compression testing are manufactured using different trajectory strategies. Frequently occurring macro- and microgeometrical defects are evaluated and categorized in order to optimize the part quality. This work also studies the effect of some manufacturing parameters such as the gap between print head and machine bed, trajectory strategy, bed leveling, and temperatures on part quality. The most suitable specimens are tested mechanically in tensile or compression tests. In the case of study, tensile strength values are only 8.6% lower than the values for reference tests on the unextruded filament. However, the properties deviate more strongly for compression tests which may be due to the selected specimen geometry.

Turning of light alloys as aluminum-based UNS A92024-T3 is broadly implemented in the manufacture of critical aircraft parts, so ensuring a good functional performance of these pieces is essential. Moreover, operational conditions of these pieces include saline environments where corrosion processes are present. In this paper, a methodology for the evaluation of the functional performance in turned pieces is proposed. Specimens affected and not affected by corrosion are compared. In addition, performance in service through tensile stress tests of these parts is considered. The results show that turning improves the functional performance of UNS A92024-T3 alloy and that corrosion can enhance the mechanical properties of this alloy.

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