Selective laser melting (SLM) and topology optimization for lighter aerospace componentes

Seabra, Miguel C.; Azevedo, José; Araújo, Aurélio L.; Reis, L.; Pinto, E.; Alves, Nuno; Santos, R.; Mortágua, João Pedro

doi:10.1016/j.prostr.2016.02.039

Cited by 167 publications

(53 citation statements)

References 11 publications

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“…Parts produced using AM are already widely used in various fields, such as the medical [9], automotive, and aerospace industries [7]. Fabricating load bearing parts using SLM, such as automotive power trains, turbine components [10], or aerospace components [11], is becoming more commonplace, therefore studying their mechanical performance is gaining further attention to cope with the widely expanding popularity for the process [12] and confirm its credibility. Recent studies have mainly considered the static tensile properties of the parts [10,13,14], with less attention so far to fatigue performance, as stated by [15].…”

Section: Introductionmentioning

confidence: 99%

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality

et al. 2016

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Selective laser melting (SLM) is being widely utilised to fabricate intricate structures used in various industries. Widening the range of applications that can benefit from such promising technology requires validating SLM parts in load bearing applications. Recent studies have mainly focussed on static loading, with minor attention to cyclic loading despite its vital importance in many applications.In this work, the fatigue performance of SLM AlSi10Mg was investigated considering the effects of surface quality and heat treatment. Compared to heat treatment, machining the samples played a minor role in improving the fatigue behaviour. This is potentially attractive to industries interested in latticed structures and topology-optimised parts where post-processing machining is not feasible. The characteristically fine microstructure in the as-built samples provided good fatigue crack propagation resistance but none of them survived nominal fatigue life of 3x10 7 cycles within the maximum stress range of 63-220 MPa. A specially-tailored heat treatment increased the material's ductility, significantly improving its fatigue performance. At 94 MPa, the heat-treated samples survived beyond the nominal fatigue life, outperforming the reference cast material. The combined effect of machining and heat treatment yielded parts with far superior fatigue properties, promoting the material for a wider range of applications.

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Section: Introductionmentioning

confidence: 99%

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality

et al. 2016

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“…Topology optimisation is normally used for lightweight design, it is based on finite element analysis and the material portions stressed insignificantly are iteratively removed to achieve the final topologically optimised forms for parts. In recent years, several aerospace applications have been researched for topology optimised lattice structures [46][47][48][49]. With the solid isotropic material approach, the structure can be designed voxel by voxel within a defined unit cell, mapping the structural density, and possibly combining multiple materials to maximise the functional performance [50].…”

Section: Optimal Design Solutionsmentioning

confidence: 99%

“…Other reports also indicated considerable weight reductions achieved through the design modifications applied to different brackets used on the Airbus A350XWB and A380 models [52][53][54]. Seabra et al employed topology optimisation and selective laser melting to manufacture a light weight aircraft bracket [49], achieving around 28% weight reduction with an improved factor of safety.…”

Section: Optimal Design Solutionsmentioning

confidence: 99%

Additive Manufacturing for the Aircraft Industry: A Review

Singamneni¹,

Lv²,

Hewitt³

et al. 2019

Research Article1J Aeronaut Aerospace Eng

110

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Considering the stringent regulations, manufacturing of aircraft parts is often quite complex and time consuming. The multi-million components, multi-tier manufacturing systems and the severe constraints surrounding the sector lead to heavy inventory investments to achieve the just-in-time supply of parts often needed to reduce the airplane ground times. Additive manufacturing evolved allowing for the direct production of complex parts based on digital data with no complex tooling or machinery, a messiah of true just in time production. Appropriate integration of additive manufacturing with the aircraft industry could resolve some of the supply chain and inventory hurdles. Significant progress is already evident in these lines, but the lack of quality assurance attributes and certification standards is hampering the progress. The state-of-the-art of the application of additive manufacturing in the aircraft industry is reviewed in this paper. The supply chain configurations of the aircraft industry, the possible roles of additive manufacturing in relaxing the pressures in the system are evaluated. The application areas, enhanced attributes, and certification standards are critically reviewed and classified. The overall growth in the application of additive manufacturing in the aircraft industry, the main hurdles, and the future possibilities are evaluated and presented systematically, clearly portraying the developments.

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“…Esse tipo de processo de fabricação foi introduzido pela primeira vez em 1986 com o advento do processo de Estereolitografia (Stereolithography -SLA) por meio da patente de Charles Hull [1]. Atualmente, a AM já é utilizada em diversas áreas como a área automotiva [2], aeroespacial [3] e médica [4,5], sendo a estereolitografia um dos processos de AM mais utilizados nos dias de hoje [6]. Essa técnica tem o potencial de ser útil em diversas aplicações como, por exemplo, na área de microfluídica [7], Sistemas MicroEletroMecânicos (Micro Electrical Mechanical Systems -MEMS) [8], estruturas porosas para tecidos vivos [9,10] e moldes [11].…”

Section: Introductionunclassified

Manufatura aditiva por estereolitografia: análise da geometria da peça e da influência da posição e orientação de fabricação

Coelho¹,

Araujo²,

Thiré³

2018

Matéria (Rio J.)

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RESUMO A estereolitografia é um dos processos de manufatura aditiva mais utilizados e utiliza resina líquida fotopolimerizável como matéria-prima. Por meio de uma reação de cura, cada camada desta resina é transformada para o estado sólido. Como qualquer tipo de processo de fabricação, a estereolitografia tem suas limitações e dificuldades, a mais comum é a contração dimensional das peças fabricadas durante a polimerização. É possível reduzir este defeito analisando os parâmetros que influenciam o fator de contração das peças produzidas, porém não foram encontrados estudos científicos que quantifiquem a influência da orientação da peça e se há influência da posição na plataforma. Neste artigo, a contração de peças fabricadas foi quantificada e a análise de variância dos resultados em diferentes orientações e localizações foi realizada. De acordo com os resultados, verificou-se que a localização das peças na plataforma é um fator importante em função das orientações das dimensões das geometrias fabricadas e portanto deve ser compensado de forma não homogênea para corrigir este defeito.

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Selective laser melting (SLM) and topology optimization for lighter aerospace componentes

Cited by 167 publications

References 11 publications

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality

Improving the fatigue behaviour of a selectively laser melted aluminium alloy: Influence of heat treatment and surface quality

Additive Manufacturing for the Aircraft Industry: A Review

Manufatura aditiva por estereolitografia: análise da geometria da peça e da influência da posição e orientação de fabricação

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