Additive Manufacturing of Aluminum Alloys for Aeronautic Applications: Advantages and Problems

Montanari, Roberto; Palombi, A.; Richetta, M.; Varone, Alessandra

doi:10.3390/met13040716

Cited by 19 publications

(10 citation statements)

References 133 publications

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“…In spite of progress in the case of developing metal composite materials [58], EOS aluminum AlSi10Mg [59,60] (Light Metal for Motorsports and Aerospace Interior Applications, provided by the EOS GmbH Electro Optical Systems in the form of a gas-atomized metal powder) was set as the material of the structure. This alloy provides a favorable price-to-performance ratio, rendering it a cost-effective selection, and it is widely used for motorsports and aerospace applications [56,61]. The chemical composition of the material is given in Table 1.…”

Section: Methodsmentioning

confidence: 99%

Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS

2023

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This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. It also eliminates the repeated export and import of data between software tools. The study includes a case study involving the steering column housing of a racing car, where Siemens NX Topology Optimization was used for optimization, and verification analysis was conducted using the NX Nastran solver. The final solution was fabricated using AlSi10Mg via direct metal laser sintering on a 3D printer and successfully validated under real conditions. In conclusion, this paper introduces a comprehensive design methodology for the direct utilization of topology optimization, which was validated through a case study, yielding positive results.

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Section: Methodsmentioning

confidence: 99%

Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS

2023

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“…High-strength aluminum alloys play an important role in the fabrication of structural components for aircraft, such as skins, wing beams, and wing ribs, owing to their advantages of low density, high strength, and good machinability [1,2]. The performance requirements of the aircraft materials are shown in Figure 1 [3].…”

Section: Introductionmentioning

confidence: 99%

Multi-Objective Optimization for Forming Quality of Laser and CMT-P Arc Hybrid Additive Manufacturing Aluminum Alloy Using Response Surface Methodology

He,

Zhang,

et al. 2024

Actuators

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A thin-walled structure of high-strength aluminum alloy 2024 (AA2024) was fabricated using novel laser and cold metal transfer and pulse (CMT-P) arc hybrid additive manufacturing (LCAHAM) technology. The influence of the wire feeding speed, scanning speed, and laser power on the forming quality was systematically studied by the response surface methodology, probability statistical theory, and multi-objective optimization algorithm. The result showed that the forming accuracy was significantly more affected by the laser power than by the wire feeding speed and scanning speed. Specifically, there was an obvious correlation between the interaction of the laser power and wire feeding speed and the resulting formation accuracy of LCAHAM AA2024. Moreover, the laser power, wire feeding speed, and scanning speed all had noticeable effects on the spattering degree during the LCAHAM AA2024 process, with the influence of the laser power surpassing that of the other two factors. Importantly, these three factors demonstrated minimal mutual interaction on spattering. Furthermore, the scanning speed emerged as the most significant factor influencing porosity compared to the wire feeding speed and laser power. It was crucial to highlight that the combined effects of the wire feed speed and laser power played an obvious role in reducing porosity. Considering the forming accuracy, spattering degree, and porosity collectively, the recommended process parameters were as follows: a wire feeding speed ranging from 4.2 to 4.3 m/min, a scanning speed between 15 and 17 mm/s, and a laser power set at approximately 2000 W, where the forming accuracy was 84–85%, the spattering degree fell within 1.0–1.2%, and the porosity was 0.7–0.9%.

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“…Subsequent ageing results in metastable alterations that greatly improve the material's strength. The most popular problem during the laser melting of cast Al-Cu alloys is the initiation and propagation of solidification cracks [18,29]. In this context, the aim of this study is to modify and suit high-strength AlCuMgMn alloy for laser melting and additive manufacturing processes by adding a combination of the refining element zirconium (Zr) and eutectic element yttrium (Y) to the cast alloy, carrying out homogenization annealing prior to laser melting, and applying a heating platform during the laser melting process to decrease the maximum possible defects that form during high laser melting applications.…”

Section: Introductionmentioning

confidence: 99%

The Effects of Zirconium and Yttrium Addition on the Microstructure and Hardness of AlCuMgMn Alloy when Applying In Situ Heating during the Laser Melting Process

Khalil,

Pozdniakov,

Solonin

et al. 2023

Materials

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This paper studies the effect of the laser melting process (LMP) on the microstructure and hardness of a new modified AlCuMgMn alloy with zirconium (Zr) and Yttrium (Y) elements. Homogenized (480 °C/8 h) alloys were laser-surface-treated at room temperature and a heating platform with in situ heating conditions was used in order to control the formed microstructure by decreasing the solidification rate in the laser-melted zone (LMZ). Modifying the AlCuMgMn alloy with 0.4 wt% Zr and 0.6 wt% Y led to a decrease in grain size by 25% with a uniform grain size distribution in the as-cast state due to the formation of Al3(Y, Zr). The homogenization dissolved the nonequilibrium intermetallic phases into the (Al) matrix and spheroidized and fragmentized the equilibrium phase’s particles, which led to the solidification of the crack-free LM zone with a nonuniform grain structure. The microstructure in the LMZ was improved by using the in situ heating approach, which decreased the temperature gradient between the BM and the melt pool. Two different microstructures were observed: ultrafine grains at the boundaries of the melted pool due to the extremely high concentration of optimally sized Al3(Y, Zr) and fine equiaxed grains at the center of the LMZ. The combination of the presence of ZrY and applying a heating platform during the LMP increased the hardness of the LMZ by 1.14 times more than the hardness of the LMZ of the cast AlCuMgMn alloy.

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Additive Manufacturing of Aluminum Alloys for Aeronautic Applications: Advantages and Problems

Cited by 19 publications

References 133 publications

Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS

Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS

Multi-Objective Optimization for Forming Quality of Laser and CMT-P Arc Hybrid Additive Manufacturing Aluminum Alloy Using Response Surface Methodology

The Effects of Zirconium and Yttrium Addition on the Microstructure and Hardness of AlCuMgMn Alloy when Applying In Situ Heating during the Laser Melting Process

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