Application of Additive Manufacturing technology to an Aerospace component for better trade-off’s

Abstract

Establishing the feasibility to Metal Additive Manufacturing has been a cumbersome task for any industry adapting this technology. Through this research we have identified few areas which needed to be discussed to establish such feasibility. Various constrains of part identification, static strength analysis, design intent, materials properties, process parameters have been identified. To evaluate our research findings, we have selected an aero structural part Flap Lever, developed a 3D model using CATIA software, and performed static strength checks, followed by optimization with respect to design intent. As part of material properties, Density issue, Surface quality, Mechanical properties, Microstructure, Residual stresses, Built up Direction and grain Orientation adopted to map design intent have been briefly mentioned. The design intent was weight optimization and savings on build to fly ratio, fuel costs, time to market etc., complimented by ease of customization with AM will give edge to this product. The generic mentions of the various constraints and their possible guidelines applied to critical structural aerospace component (flap lever) will be able pave path towards better application of critical aerospace parts with similar design intent.