Additive Manufacturing of Ti-6Al-4V Aero Engine Parts: Qualification for Reliability

Samuel, Mathews P.; Mishra, Aditya Kumar; Mishra, R. K.

doi:10.1007/s11668-018-0393-9

Cited by 18 publications

(5 citation statements)

References 6 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Following the concept of integrated PSPP simulations, the grain structure was computationally predicted using the physically based CAFD approach proposed in [138]. The grain behaviour was described by a phenomenological model which related the yield stress of individual grains with their size and orientation through Equations ( 10) and (11). The analysis of local stress and strain fields showed that the strain localisation regions were mainly formed in the bottom region of the LPBF model sample where the grain selection had not yet occurred, particularly along the boundaries of fine elongated grains (Figures 10 and 11).…”

Section: Two-dimensional Microstructure-based Mechanical Simulationsmentioning

confidence: 99%

“…Even small changes in parameters might trigger unexpected and previously unexplored effects and unwanted defects in a resulting component, making predictability a significant challenge. This is often inappropriate for highdemanding sectors such as the aerospace and health industries [11,12]. MAM still suffers from many scientific, technological, and economic issues, which underscores the need for a sophisticated understanding of the technology's physics [13].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

View full text Add to dashboard Cite

In the rapidly evolving field of additive manufacturing (AM), the predictability of part properties is still challenging due to the inherent multiphysics complexity of the technology. This results in time-consuming and costly experimental guess-and-check approaches for manufacturing each individual design. Through synthesising advancements in the field, this review argues that numerical modelling is instrumental in mitigating these challenges by working in tandem with experimental studies. Unique hierarchical microstructures induced by extreme AM process conditions– including melt pool patterns, grains, cellular–dendritic substructures, and precipitates—affect the final part properties. Therefore, the development of microstructure-informed mechanical models becomes vital. Our review of numerical studies explores various modelling approaches that consider the microstructural features explicitly and offers insights into multiscale stress–strain analysis across diverse materials fabricated by powder bed fusion AM. The literature indicates a growing consensus on the key role of multiscale integrated process–structure–property–performance (PSPP) modelling in capturing the complexity of AM-produced materials. Current models, though increasingly sophisticated, still tend to relate only two elements of the PSPP chain while often focusing on a single scale. This emphasises the need for integrated PSPP approaches validated by a solid experimental base. The PSPP paradigm for AM, while promising as a concept, is still in its infantry, confronting multifaceted challenges that require in-depth, multidisciplinary expertise. These challenges range from accounting for multiphysics phenomena (e.g., advanced laser–material interaction) and their interplay (thermo-mechanical and microstructural evolution for simulating Type II residual stresses), accurately defined assumptions (e.g., flat molten surface during AM or purely epitaxial solidification), and correctly estimated boundary conditions for each element of the PSPP chain up to the need to balance the model’s complexity and detalisation in terms of both multiphysics and discretisation with efficient multitrack and multilayer simulations. Efforts in bridging these gaps would not only improve predictability but also expedite the development and certification of new AM materials.

show abstract

Section: Two-dimensional Microstructure-based Mechanical Simulationsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

View full text Add to dashboard Cite

show abstract

“…As AM products are process-sensitive, the lack of production constraints can compromise the geometrical accuracy and the quality of as-built AM parts when manufactured in large quantities. These could be attributed to critical issues such as gas porosity, internal cracks, lack of fusion between layers, and microstructural aberrations as a result of the lack of in situ process monitoring [148]. The development of in situ sensing and feedback control would help minimize build errors and reduce the need for subsequent expensive tests [149].…”

Section: Non-destructive Testing Evaluation and In-situ Process Monmentioning

confidence: 99%

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Yusuf

Cutler

Gao

2019

Metals

199

View full text Add to dashboard Cite

Metal additive manufacturing (AM) has matured from its infancy in the research stage to the fabrication of a wide range of commercial functional applications. In particular, at present, metal AM is now popular in the aerospace industry to build and repair various components for commercial and military aircraft, as well as outer space vehicles. Firstly, this review describes the categories of AM technologies that are commonly used to fabricate metallic parts. Then, the evolution of metal AM used in the aerospace industry from just prototyping to the manufacturing of propulsion systems and structural components is also highlighted. In addition, current outstanding issues that prevent metal AM from entering mass production in the aerospace industry are discussed, including the development of standards and qualifications, sustainability, and supply chain development.

show abstract

“…With the increased use and widespread adoption of AM, a number of reliability and repeatability needs arise for high-performance AM processes in the industry. Considering the functional use of AM produced parts in production, the geometrical performance of a printed part and its conformance to geometrical tolerances are of great importance (Samuel et al, 2018;Barari et al, 2017;Sun et al, 2017;Turner and Gold, 2015). However, due to the complex physics involved in many AM processes, the process dynamics and geometrical features of the finished part are difficult to model and analyze (N. Turner et al, 2014;Aksoy et al, 2020;Pellegrino et al, 2016).…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental analysis of bead cross-sectional geometry in fused filament fabrication

Balta

Altınkaynak

2022

RPJ

View full text Add to dashboard Cite

Purpose This paper aims to develop experimentally validated numerical models to accurately characterize the cross-sectional geometry of the deposited beads in a fused filament fabrication (FFF) process under various process conditions. Design/methodology/approach The presented numerical model is investigated under various fidelity with varying computational complexity. To this end, comparisons between the Newtonian, non-newtonian, isothermal and non-isothermal computational models are presented for the extrusion of polylactic acid material in an FFF process. The computational model is validated through an experimental study on an off-the-shelf FFF printer. Microscope images of experimentally printed FFF bead cross-sections corresponding to various printing conditions are digitally processed for the validation. In the experimental study, common practical printing conditions for an FFF process are tested, and the results are compared to the numerical model. Findings Microscope image analyses of the cross-sectional geometries of deposited beads show that the numerical model provides a precise characterization of the cross-sectional geometry under varying process parameters in terms of the cross-section outline, bead height and width. The results show that the nozzle-to-table distance has a great effect on the bead shape when compared to the extrusion rate at a given nozzle-to-table distance. Comparison of the various computational models show that the non-Newtonian isothermal model provides the best tradeoff between computational complexity and model accuracy. Originality/value The authors provide detailed computational models, including the extruder nozzle geometry for cases ranging from Newtonian isothermal models to non-Newtonian non-isothermal models with experimental validation. The validation study is conducted for practical process parameters that are commonly used in FFF in practice and show that the computational models provide an accurate depiction of the true process outputs. As the developed models can accurately predict process outputs, they can be used in further applications for process planning and parameter tuning.

show abstract

Additive Manufacturing of Ti-6Al-4V Aero Engine Parts: Qualification for Reliability

Cited by 18 publications

References 6 publications

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Numerical and experimental analysis of bead cross-sectional geometry in fused filament fabrication

Contact Info

Product

Resources

About