Metal additive manufacturing of commercial aerospace components – A comprehensive review

Abstract

Metal additive manufacturing (AM) has matured and grown from its infancy in the research stage to the fabrication of new and advanced components for its supreme applications. AM is a lead for the advanced manufacturing processes with an increased and advanced potential to revolutionize the manufacturing domain. It could exhibit a progressive change in the project and design paradigms. In the past decade, the use of metal AM process in the aerospace industry to build, repair various components for military applications and several outer space vehicle fabrications have occupied higher potential among various other manufacturing industries. In addition to it, many studies have made it a more versatile, common, and safer technology for the design and fabrication of components with the introduction of novel processes, materials, technologies, cost efficiency, and process design. In the present review article, the use of advanced aluminum alloys in the AM of fuselage, horizontal stabilizer, and high and low wings has gained increased advantages in the aerospace industry. Various components of wings and fuselage with its merits and demerits in AM processing are discussed. The outstanding issues in AM process and steps to overcome with post-processing techniques are elaborated. Finally, the future scope and research directions of the AM process involved in the fabrication of selected components are discussed.

The semi-quantitative analysis of hole defects in metal additive manufacturing components using LIBS

“…Due to the layer-by-layer accumulation of materials, the production process is nearly net forming, which can reduce the wastage of materials and improve the utilization rate of materials. AM technology is widely used in medical, 2,3 transportation, 4 aviation 5,6 and other fields. However, during the printing process, metal AM parts may present many material discontinuities 7 which affect the quality of the parts.…”

Microhardness and Tensile Strength Analysis of SS316L/CuCrZr Interface by Laser Powder Bed Fusion

“…Additive Manufacturing (AM) technology, as a novel manufacturing method, is distinguished by its rapid molding speed, high manufacturing precision, and excellent mechanical properties [ 12 , 13 , 14 ]. Currently, it is employed in a number of fields, including aerospace [ 15 , 16 ], automotive [ 17 , 18 ], biomedical [ 19 , 20 ], and others. In the field of nuclear engineering, numerous industry norms and standards prohibit the utilization of AM components.…”

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

“…Advancements in additive manufacturing (AM) are being driven by faster machines utilizing multiple lasers, new materials optimized for powder-bed fusion processes, and more intelligent software leveraging artificial intelligence/machine learning (AI/ML) [1][2][3]. These developments are making AM methods a viable solution for a wide range of realworld production applications.…”