Additive manufacturing for the aerospace industry / edited by Francis Froes, Rodney Boyer.

Format:

Book

Contributor:

Froes, Francis, editor.

Boyer, Rodney, editor.

Language:

English

Subjects (All):

Aerospace engineering.

Three-dimensional printing.

Physical Description:

1 online resource (483 pages)

Place of Publication:

Amsterdam, Netherlands : Elsevier, [2019]

Summary:

Additive Manufacturing for the Aerospace Industry explores the design, processing, metallurgy and applications of additive manufacturing (AM) within the aerospace industry. The book's editors have assembled an international team of experts who discuss recent developments and the future prospects of additive manufacturing. The work includes a review of the advantages of AM over conventionally subtractive fabrication, including cost considerations. Microstructures and mechanical properties are also presented, along with examples of components fabricated by AM. Readers will find information on a broad range of materials and processes used in additive manufacturing.It is ideal reading for those in academia, government labs, component fabricators, and research institutes, but will also appeal to all sectors of the aerospace industry.- Provides information on a broad range of materials and processes used in additive manufacturing- Presents recent developments in the design and applications of additive manufacturing specific to the aerospace industry- Covers a wide array of materials for use in the additive manufacturing of aerospace parts- Discusses current standards in the area of aerospace AM parts

Contents:

Front Cover

Additive Manufacturing for the Aerospace Industry

Copyright Page

Contents

List of Contributors

1 Introduction to aerospace materials requirements and the role of additive manufacturing

1.1 Aerospace materials and their requirements

1.2 Additive manufacturing

1.3 Additive manufacturing fabrication of various types of materials

1.4 Contents of this book

References

2 Review of additive manufacturing technologies and applications in the aerospace industry

2.1 Aerospace requirements and opportunities for additive manufacturing

2.1.1 Design requirements

2.1.1.1 Structural design

2.1.1.2 Functional complexity

2.1.1.3 Property requirements

2.1.2 Manufacturing capabilities and benefits

2.1.2.1 Part consolidation

2.1.2.2 Material economy

2.1.2.3 Small production runs and turnaround time

2.2 Additive manufacturing technologies

2.2.1 Additive metal technologies

2.2.1.1 Directed energy deposition

2.2.1.2 Powder bed fusion

2.2.1.3 Other relevant additive metal technologies

2.2.2 Additive nonmetal technologies

2.2.2.1 Selective laser sintering

2.2.2.2 Stereolithography

2.2.2.3 PolyJet

2.2.2.4 Fused deposition modeling

2.3 Additive manufacturing applications

2.3.1 Direct digital manufacturing

2.3.1.1 Direct metal part fabrication

2.3.1.2 Fixtures and accessories

2.3.2 Rapid tooling

2.3.3 Rapid prototyping

2.3.4 Repair

2.3.4.1 Geometry restoration

2.3.4.2 Structural integrity restoration

2.4 Challenges and potential future applications

2.4.1 Challenges

2.4.1.1 Manufacturing limitations

2.4.1.2 Postprocessing realities

2.4.1.3 Specification and standard development

2.4.2 Potential future applications

3 Qualification and certification of metal additive manufactured hardware for aerospace applications.

3.1 Introduction

3.2 Special considerations for fracture-critical hardware

3.3 Current qualification and certification state-of-the-art and gap analysis

3.3.1 Standardization gaps related to qualification and certification

3.3.2 Recent directions in qualification, certification, and quality control for additive manufacturing

3.4 Industry qualification and certification approaches

3.4.1 General Electric qualification and certification approach

3.4.1.1 Qualification of additive materials

3.4.1.2 Certification of additive materials

3.4.1.3 Quality control in additive materials

3.4.2 Lockheed Martin qualification and certification approach

3.5 Government agency approaches

3.5.1 National aeronautics and space administration qualification and certification approach

3.5.1.1 General qualification requirements

3.5.1.2 Additive manufacturing part categories

3.5.1.3 Integrated structural integrity rationale

3.5.1.4 Influence of mission classification

3.5.1.5 Tailoring approach

3.5.1.6 Industry standards

3.5.1.7 Process specifications

3.5.1.8 Procurement specifications

3.5.1.9 Additional guidance

3.5.1.10 Warnings

3.5.2 Federal Aviation Administration qualification and certification approach

3.6 Summary and recommendations

Acknowledgments

4 Design for metal additive manufacturing for aerospace applications

4.1 Introduction

4.2 Methods and approaches

4.2.1 Topological optimization

4.2.2 Part consolidation

4.2.3 Part integration and repair

4.2.4 Other techniques

4.3 Process aspects of design

4.3.1 Part performance

4.3.1.1 Microstructure

4.3.1.2 Defects

4.3.1.3 Mechanical properties

4.3.2 Part quality

4.3.3 Part evaluation: in-situ and after process nondestructive evaluation (NDE)

4.3.4 Post processing

4.4 Cost considerations.

4.5 Product and process design tools

4.5.1 Additive manufacturing design software

4.5.2 Additive manufacturing process software

4.6 Conclusions

5 Structure formation in A.M. processes of Titanium and Ni-base alloys

5.1 Evaluation of the structure of powder particles of different sizes

5.2 A dependence of the microstructure of powder particles in the initial state on their size

5.3 Determination of changes in the structure using samples produced by different additive technologies

5.4 Testing of mechanical properties of samples of parts produced by direct metal deposition and selective laser melting

5.5 Conclusions

Acknowledgement

Reference

Further reading

6 Measurement of powder characteristics and quality for additive manufacturing in aerospace alloys

6.1 Introduction

6.2 Quality control measurements

6.2.1 Particle size and distribution

6.2.2 Apparent density and flow

6.2.3 Tap density

6.2.4 Moisture analysis

6.2.5 Inclusion analysis

6.2.6 Shape factor

6.2.7 Porosity

6.3 Advanced metallographic techniques

6.3.1 Background

6.3.2 Metallographic sample preparation

6.3.2.1 Sampling

6.3.2.2 Mounting

6.3.2.3 Grinding and polishing

6.3.3 Light optical microscopy-automated image analysis

6.3.4 Shape and texture analysis

6.3.4.1 Shape analysis

6.3.5 Microstructural analysis

6.3.6 Chemical analysis

7 The processing and heat treatment of selective laser melted Al-7Si-0.6Mg alloy

7.1 Selective laser melted Al alloy A357

7.1.1 Process control

7.1.2 Density optimization

7.2 Post selective laser melting heat treatment

7.2.1 Tensile properties

7.2.2 Fractography

7.3 Refinement of laser melting and postprocessing parameters

7.3.1 The selection of optimized heat treatment parameters.

7.3.2 The selection of optimized laser parameters

7.3.3 Tensile properties

7.3.4 Fractography

7.4 Conclusions

8 Superalloys, powders, process monitoring in additive manufacturing

8.1 Applications: materials in gas turbines

8.2 Material and processing challenges in additive manufacturing of superalloys and different approaches for solutions

8.2.1 Challenges with additive manufacturing-theory on weldability issues

8.2.2 Solidification cracking

8.2.3 Liquation cracking (HAZ)

8.2.4 Strain-age cracking

8.2.5 Ductility dip cracking

8.3 Powder material properties

8.4 Process monitoring

8.4.1 Quality assurance in AM

8.4.2 Challenges with tradition postprocess inspection techniques

8.4.3 Novel QA approaches

8.5 Sensor types for in situ process monitoring

8.5.1 Optical in situ process monitoring systems for AM

8.5.1.1 Photodiode-based process monitoring

8.5.1.2 Camera-based process monitoring

8.5.1.3 Nonoptical sensor technologies

8.6 Quality assurance tie-in

8.7 Defect data correlation automated, future closed-loop control possibilities

9 Fusion and/or solid state additive manufacturing for aerospace applications

9.1 Introduction

9.2 Experimental examples

10 Profile electron beam 3D metal printing

Summary

11 Additive manufacturing of titanium aluminides

11.1 Applications of TiAl

11.2 Fundamentals of TiAl

11.3 Processings of TiAl

11.3.1 Casting

11.3.2 Wrought processing

11.3.3 Powder metallurgy

11.3.4 Additive manufacturing

11.4 Laser metal deposition of TiAl

11.5 Selective laser melting of TiAl

11.6 Electron beam melting of TiAl

11.7 Summary and prospects

Further reading.

12 Aerospace applications of the SLM process of functional and functional graded metal matrix composites based on NiCr supe...

12.1 Introduction

12.2 Metal matrix composites fabrication via additive technologies

12.3 Metal matrix composites on the nickel alloy based

12.4 Methods and materials

12.5 Results and discussion

12.6 Conclusions

13 Surface roughness and fatigue properties of selective laser melted Ti-6Al-4V alloy

13.1 Introduction

13.1.1 Surface roughness of selective laser melted metallic components

13.1.2 Post-selective laser melting surface treatment

13.1.3 Fatigue performance of selective laser melted Ti-6AL-4V

13.2 Experimental procedure

13.2.1 Material

13.2.2 Selective laser melting of Ti-6Al-4V specimens

13.2.3 Surface roughness measurements

13.2.4 Postselective laser melting heat treatment of fatigue samples

13.2.5 Fatigue testing

13.3 Results and discussion

13.3.1 Surface roughness

13.3.1.1 Ra versus inclination angle and processing parameters

13.3.1.2 Effect of contour scan on surface texture

13.3.2 Fatigue properties

13.4 Conclusions

14 Aluminum alloys for selective laser melting - towards improved performance

14.1 Introduction

14.2 Processing-microstructure-property considerations for current alloys in selective laser melting

14.3 Alloy and process design for improved performance

14.3.1 Design of new alloys for selective laser melting

14.3.2 Adaptation of existing high strength alloys for selective laser melting

14.3.3 Development of composite materials for selective laser melting

14.4 Summary and outlook

15 Additive aerospace considered as a business

15.1 3D printing technologies for tooling and prototyping.

15.2 Factors driving additive manufacturing in the aerospace industry.

Notes:

Description based on print version record.

ISBN:

9780128140635

0128140631

9780128140628

0128140623