Purpose
The purpose of this paper is to identify and define the certification lifecycle of laser powder bed fusion for aerospace applications from equipment acquisition and installation to production, part acceptance and continuous improvement activities.
Design/methodology/approach
A top–down systems engineering approach is performed consisting of concept development, requirements engineering and systems architecting. This approach is taken from the perspective of a production organization.
Findings
A certification roadmap is proposed that references industry requirements at the relevant phases of the roadmap. Each phase of the roadmap acts as a decision gate for progression to the next.
Originality/value
Qualification and certification of metal laser powder bed fusion is currently a challenge within the aerospace industry. From an aerospace point of view, the qualification and certification of this relatively new manufacturing process should not have to be any different from traditional manufacturing processes, although with extensive quality control and regulatory oversight. This paper proposes a means for fulfilling these requirements chronologically and provides guidance on ensuring such quality control throughout the manufacturing system lifecycle. This roadmap provides insight into the qualification and certification of laser powder bed fusion for aerospace applications and provides value for future industrial feasibility studies.
Metal powders are key to metal additive manufacturing technologies such as powder bed fusion. These powder feedstocks experience a range of forces and physical phenomena both during the powder bed fusion process and additional post-processing stages that can alter their composition and material properties. To evaluate such effects, these powders need to be characterized, tested, and analyzed at critical stages of their lifecycles. This paper provides a review of the current state of the art for powder evaluation methods and their applicability for powder bed fusion production. Methods are categorized by the properties they evaluate, either particulate or bulk properties. Industry standards are identified for each method if applicable and the advantages and disadvantages of each are defined. Effects of these properties on the flowability and spreadability of powders are synthesized and practical management guidelines are defined. This paper aims at providing an overview of powder evaluation for powder bed fusion, practical considerations for the development of powder test and evaluation programs, and provide insights for future research undertakings in the field.
This study aims to develop a conceptual framework for the certification of laser powder bed fusion quality management systems for aerospace applications. This research is structured around industry standards and best practices. The developed framework consists of a process map that identifies the required processes and activities for the realisation of parts. Industry standards and best practices are referenced to form standard operating procedures. The framework was presented to subject matter experts within the industry and academia, whose feedback was positive.
OPSOMMINGHierdie studie stel ʼn konseptuele raamwerk voor vir die sertifisering van laserpoeierbed laagvervaardigingsproses kwaliteitsbestuurstelsels vir lugen ruimtevaart toepassings. Hierdie navorsing is gestruktureer rondom bedryfstandaarde en beste praktyke. Die ontwikkelde raamwerk bestaan uit ʼn proseskaart wat die vereiste prosesse en aktiwiteite vir die realisering van onderdele identifiseer. Daar word verwys na bedryfstandaarde en beste praktyke in die vorm van standaardprosedures. Die raamwerk was aangebied aan industrie-en akademie vakkundiges, en die terugvoer was positief.
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