Metal additive manufacturing in aerospace: A review

Blakey-Milner, Byron Alexander; Gradl, Paul R.; Snedden, Glen; Brooks, Michael J.; Pitot, Jean; López, Elena; Leary, Martin; Berto, Filippo; Plessis, Anton du

doi:10.1016/j.matdes.2021.110008

Cited by 881 publications

(265 citation statements)

References 200 publications

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“…Obtaining permanent joints from dissimilar metals is an urgent challenge, not only in the field of laser welding of dissimilar metals but also in such promising and science-intensive manufacturing areas as additive technologies (Direct Metal Deposition, (DMD), Selective Laser Melting (SLM)) [ 95 , 96 , 97 , 98 ] and technology of recovery cladding [ 99 , 100 ]. They also have problems with cracking, poor wettability, and flowability of the molten metal.…”

Section: Discussionmentioning

confidence: 99%

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Kuryntsev

2021

Materials

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Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.

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Section: Discussionmentioning

confidence: 99%

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Kuryntsev

2021

Materials

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“…For situation (3), the molten pool temperature is higher than the Tb_cu, and the fusion track can be obtained in the keyhole mode. Firstly, the parameters for situation (1) are excluded because no fusion occurred between the copper substrate and steel powder. Secondly, the keyhole mode can lead to a porosity void with vapor entrapping at the bottom of the molten pool [49,50] as well as a high dilution of the molten pool [51], which is not expected to produce good mechanical properties.…”

Section: Printability Maps For the First Layermentioning

confidence: 99%

“…Multi-material components (MMC), such as gradient materials, dissimilar joints, and sandwich structure materials, are characterized by spatial composition variation in one or more directions [1]. Due to their unique properties with progressive change in performance and function, MMC has gained notable attention and has been widely used in many fields such as electrical and aerospace over the past few decades [2].…”

Section: Introductionmentioning

confidence: 99%

A Layer-Dependent Analytical Model for Printability Assessment of Additive Manufacturing Copper/Steel Multi-Material Components by Directed Energy Deposition

Zhang

Xiao

et al. 2021

Micromachines

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Copper/steel bimetal, one of the most popular and typical multi-material components (MMC), processes excellent comprehensive properties with the high strength of steel and the high thermal conductivity of copper alloy. Additive manufacturing (AM) technology is characterized by layer-wise fabrication, and thus is especially suitable for fabricating MMC. However, considering both the great difference in thermophysical properties between copper and steel and the layer-based fabrication character of the AM process, the optimal processing parameters will vary throughout the deposition process. In this paper, we propose an analytical calculation model to predict the layer-dependent processing parameters when fabricating the 07Cr15Ni5 steel on the CuCr substrate at the fixed layer thickness (0.3 mm) and hatching space (0.3 mm). Specifically, the changes in effective thermal conductivity and specific heat capacity with the layer number, as well as the absorption rate and catchment efficiency with the processing parameters are considered. The parameter maps predicted by the model have good agreement with the experimental results. The proposed analytical model provides new guidance to determine the processing windows for novel multi-material components, especially for the multi-materials whose physical properties are significantly different.

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“…Direct Laser Deposition (DLD) is one of the most widely utilized additive manufacturing (AM) technologies for the production of Ti-6Al-4V alloy parts. The uneven local heating of the buildup during DLD leads to significant stresses and distortion that affect the service properties and the shape of the final parts [1][2][3]. In the last, decade numerous models have been proposed for the simulation of these phenomena [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Effect of Elevated Temperatures on the Mechanical Properties of a Direct Laser Deposited Ti-6Al-4V

et al. 2021

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In the present work, the mechanical properties of the DLD-processed Ti-6Al-4V alloy were obtained by tensile tests performed at different temperatures, ranging from 20 °C to 800 °C. Thereby, the process conditions were close to the conditions used to produce large-sized structures using the DLD method, resulting in specimens having the same initial martensitic microstructure. According to the obtained stress curves, the yield strength decreases gradually by 40% when the temperature is increased to 500 °C. Similar behavior is observed for the tensile strength. However, further heating above 500 °C leads to a significant increase in the softening rate. It was found that the DLD-processed Ti-6Al-4V alloy had a Young’s modulus with higher thermal stability than conventionally processed alloys. At 500 °C, the Young’s modulus of the DLD alloy was 46% higher than that of the wrought alloy. The influence of the thermal history on the stress relaxation for the cases where 500 °C and 700 °C were the maximum temperatures was studied. It was revealed that stress relaxation processes are decisive for the formation of residual stresses at temperatures above 700 °C, which is especially important for small-sized parts produced by the DLD method. The coefficient of thermal expansion was investigated up to 1050 °C.

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Metal additive manufacturing in aerospace: A review

Cited by 881 publications

References 200 publications

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

A Layer-Dependent Analytical Model for Printability Assessment of Additive Manufacturing Copper/Steel Multi-Material Components by Directed Energy Deposition

Effect of Elevated Temperatures on the Mechanical Properties of a Direct Laser Deposited Ti-6Al-4V

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