Development of a production approach to build a titanium flaperon rib by directed energy deposition
Tóm tắt
Laser powder-directed energy deposition (LP-DED) is gaining interest in the production of complex large parts at a high production rate compared to conventional machining. Typically, these products are milled out of solid blocks. The aim of this work is to show the whole production chain to manufacture a titanium flaperon rib starting from the process optimisation to production and post-processing of the part itself. First, the process parameters for thin and bulky structures were optimised in LP-DED. Then different characteristic design features of the rib were defined and the manufacturing strategies were optimised. Lastly, all optimised strategies were applied for the production of the full-scale flaperon ribs. In this work, several design guidelines and optimum process conditions were obtained for Ti6Al4V processed by LP-DED. On one hand, the process parameters for thin walls and solid features were obtained. In addition, intersections and overhang structures were studied to achieve stable and high-quality connections. On the other hand, different strategies for reducing the deformations were studied and minimum deformations were obtained for large slender build plates. All developed strategies were implemented to successfully produce a large-sized flaperon rib in Ti6Al4V by powder LP-DED.
Tài liệu tham khảo
Blakey-Milner B et al (2021) Metal additive manufacturing in aerospace: a review. Mater Des 209:110008. https://doi.org/10.1016/j.matdes.2021.110008
Wang J et al (2022) Effects of scanning strategies on residual stress and deformation by high-power direct energy deposition: Island size and laser jump strategy between islands. J Manuf Process 75:23–40. https://doi.org/10.1016/j.jmapro.2021.12.054
Gebler M, Uiterkamp AJMS, Visser C (2014) A global sustainability perspective on 3D printing technologies. Energy Policy 74:158–167. https://doi.org/10.1016/j.enpol.2014.08.033
Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; part II: Mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35. https://doi.org/10.1016/j.addma.2015.07.002
Liu Z, He B, Lyu T, Zou Y (2021) A review on additive manufacturing of titanium alloys for aerospace applications: directed energy deposition and beyond Ti-6Al-4V. JOM 73(6):1804–1818. https://doi.org/10.1007/s11837-021-04670-6
Clark D, Whittaker MT, Bache MR (2011) Microstructural characterization of a prototype titanium alloy structure processed via direct laser deposition (DLD). Metall Mater Trans B 43:388–396
Saboori A, Gallo D, Biamino S, Fino P, Lombardi M (2017) An overview of additive manufacturing of titanium components by directed energy deposition: microstructure and mechanical properties. Appl Sci 7:9. https://doi.org/10.3390/app7090883
ASTM International, “F3413–2019 Guide for Additive Manufacturing - Design - Directed Energy Deposition. 2019.