Qualification and certification of metal additive manufactured hardware for aerospace applications

Russell, Richard; Wells, David; Waller, Jess; Poorganji, Behrang; Ott, Eric; Nakagawa, Tsuyoshi; Sandoval, Héctor; Shamsaei, Nima; Seifi, Mohsen

doi:10.1016/b978-0-12-814062-8.00003-0

Cited by 45 publications

(18 citation statements)

References 17 publications

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“…Despite all the advances in additive technologies and the growing number of applications, many attempts to qualify load-bearing structural parts are a very difficult challenge, and many parts in the aviation sector do not pass certification tests [17][18][19][20][21][22]. Additive products have a wide range of utility, and structural and mechanical specifications.…”

Section: Introductionmentioning

confidence: 99%

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

et al. 2022

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This paper aims at an in-depth and comprehensive analysis of mechanical and microstructural properties of AISI 316L austenitic stainless steel (W. Nr. 1.4404, CL20ES) produced by laser powder bed fusion (LPBF) additive manufacturing (AM) technology. The experiment in its first part includes an extensive study of the anisotropy of mechanical and microstructural properties in relation to the built orientation and the direction of loading, which showed significant differences in tensile properties among samples. The second part of the experiment is devoted to the influence of the process parameter focus level (FL) on mechanical properties, where a 48% increase in notched toughness was recorded when the level of laser focus was identical to the level of melting. The FL parameter is not normally considered a process parameter; however, it can be intentionally changed in the service settings of the machine or by incorrect machine repair and maintenance. Evaluation of mechanical and microstructural properties was performed using the tensile test, Charpy impact test, Brinell hardness measurement, microhardness matrix measurement, porosity analysis, scanning electron microscopy (SEM), and optical microscopy. Across the whole spectrum of samples, performed analysis confirmed the high quality of LPBF additive manufactured material, which can be compared with conventionally produced material. A very low level of porosity in the range of 0.036 to 0.103% was found. Microstructural investigation of solution annealed (1070 °C) tensile test samples showed an outstanding tendency to recrystallization, grain polygonization, annealing twins formation, and even distribution of carbides in solid solution.

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Section: Introductionmentioning

confidence: 99%

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

et al. 2022

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“…The quality and cost of AM parts vary considerably. For example, in the aerospace industry, complete qualification of new AM materials and processes often requires thousands of individual tests, costs millions of dollars and takes 5 to 15 years to complete (Brice, 2011; Najmon et al , 2019; Russell et al , 2019). In the orthopedic-implant industry, on the other hand, AM technologies can fabricate low-cost, high-quality knee and hip joints routinely in a few months (Nakano and Ishimoto, 2015).…”

Section: Introductionmentioning

confidence: 99%

A functional modeling approach for quality assurance in metal additive manufacturing

Seo

Ahsan

Lee

et al. 2021

RPJ

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Purpose Due to the complexity of and variations in additive manufacturing (AM) processes, there is a level of uncertainty that creates critical issues in quality assurance (QA), which must be addressed by time-consuming and cost-intensive tasks. This deteriorates the process repeatability, reliability and part reproducibility. So far, many AM efforts have been performed in an isolated and scattered way over several decades. In this paper, a systematically integrated holistic view is proposed to achieve QA for AM. Design/methodology/approach A systematically integrated view is presented to ensure the predefined part properties before/during/after the AM process. It consists of four stages, namely, QA plan, prospective validation, concurrent validation and retrospective validation. As a foundation for QA planning, a functional workflow and the required information flows are proposed by using functional design models: Icam DEFinition for Function Modeling. Findings The functional design model of the QA plan provides the systematically integrated view that can be the basis for inspection of AM processes for the repeatability and qualification of AM parts for reproducibility. Research limitations/implications A powder bed fusion process was used to validate the feasibility of this QA plan. Feasibility was demonstrated under many assumptions; real validation is not included in this study. Social implications This study provides an innovative and transformative methodology that can lead to greater productivity and improved quality of AM parts across industries. Furthermore, the QA guidelines and functional design models provide the foundation for the development of a QA architecture and management system. Originality/value This systematically integrated view and the corresponding QA plan can pose fundamental questions to the AM community and initiate new research efforts in the in-situ digital inspection of AM processes and parts.

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“…Moreover, the aerospace components are commonly made of difficult to machine materials such as high resistant super-alloys [77]. General Electric (GE) Aviation uses Concept Laser and Arcam metal printers to manufacture fuel nozzles for its new LEAP engine [10,78]. Figure 5a shows the LEAP fuel nozzle, which is 25% lighter and stronger than the original nozzle.…”

Section: Aerospacementioning

confidence: 99%

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

et al. 2021

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In recent years, Additive Manufacturing (AM), also called 3D printing, has been expanding into several industrial sectors due to the technology providing opportunities in terms of improved functionality, productivity, and competitiveness. While metal AM technologies have almost unlimited potential, and the range of applications has increased in recent years, industries have faced challenges in the adoption of these technologies and coping with a turbulent market. Despite the extensive work that has been completed on the properties of metal AM materials, there is still a need of a robust understanding of processes, challenges, application-specific needs, and considerations associated with these technologies. Therefore, the goal of this study is to present a comprehensive review of the most common metal AM technologies, an exploration of metal AM advancements, and industrial applications for the different AM technologies across various industry sectors. This study also outlines current limitations and challenges, which prevent industries to fully benefit from the metal AM opportunities, including production volume, standards compliance, post processing, product quality, maintenance, and materials range. Overall, this paper provides a survey as the benchmark for future industrial applications and research and development projects, in order to assist industries in selecting a suitable AM technology for their application.

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Qualification and certification of metal additive manufactured hardware for aerospace applications

Cited by 45 publications

References 17 publications

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

A functional modeling approach for quality assurance in metal additive manufacturing

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

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