Abstract
Selective laser melting SLM is investigated through a study of redesign and characterization of an aeronautic part made of titanium Ti6Al4V. The part must ensure an excellent static and fatigue behaviour. The methodology developed hereby follows 3 main steps: First, the influence of laser power, laser speed and hatch distance on the amount/rate of porosity is performed to define optimized process parameters. Then, the influence of building process strategy, i.e. building direction or as-built surface roughness on the static and fatigue behaviour are studied and understood by following a vast experimental campaign. Obtained properties are finally used in a topology optimization study to find the best compromise between part weight and fatigue behavior . 3 prototypes of simulated part are produced and then characterized. Fatigue tests are conducted on the component and confirm the fatigue design proposed. Obtained results are encouraging and illustrate the fatigue design optimization of a complex Additive Manufacturing component.
Highlights
Additive layer manufacturing processes like Selective Laser Melting (SLM) enable the fabrication of highly precise and complex component geometries that are otherwise difficult, costly, or even impossible to realize using conventional techniques [1]
This study highlights importance of energy density on part density and a minimal value of energy density ensuring a good cohesion of particles for Ti6Al4V of 60J/mm3
Investigation of crack initiation mechanisms highlight that fatigue behavior is mainly controlled by surface notch or defects LOF
Summary
Additive layer manufacturing processes like Selective Laser Melting (SLM) enable the fabrication of highly precise and complex component geometries that are otherwise difficult, costly, or even impossible to realize using conventional techniques [1]. These capabilities are seen by many manufacturer as a way to improve part functionality, to reduce weight and emission for transport, to optimize supply chain and many others modern challenges. The French project FATAL (Fabrication Additive Titane Aluminium) managed by IRT Jules Verne has for main objectives to better understand process parameter impact on material properties, to generate a database for industrial designers and correlate this data base with industrial use cases
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