Abstract
Selective Laser Melting (SLM) of magnesium alloys is the technology undergoing dynamic development in many research centres. The results are promising and make it possible to manufacture defect-free material with better properties than those offered by the manufacturing technologies used to date. This review aims to evaluate present state as well as main challenges of using Laser Powder Bed Fusion (L-PBF) for processing magnesium alloys as an alternative way to conventional technologies to manufacture parts in the aerospace industry. This literature review is the first one to outline information concerning the potential to use magnesium alloys in the aerospace industry as well as to summarise the results of magnesium alloy processing using AM technologies, in particular L-PBF. The available literature was reviewed to gather information about: the use of magnesium alloys in the aerospace industry—the benefits and limitations of using magnesium and its alloys, examples of applications using new processing methods to manufacture aerospace parts, the benefits and potential of using L-PBF to process metallic materials, examples of the use of L-PBF to manufacture aerospace parts, and state-of-the-art research into L-PBF processing of magnesium and magnesium alloys.
Highlights
Over 80% of all innovations in the aerospace industry owe their existence to the use of new materials and new technologies [1]
All of the technologies mentioned above share the principle of operation, that is, the powder bed is melted as a result of interaction with the source of energy: either a laser beam (L-powder bed fusion (PBF)/Selective Laser Melting (SLM)/DMLS, SLS) or an electron beam (EBM) [43] (Fig. 5)
The methods of shaping magnesium alloy products used to date such as forging, casting, or equal-channel angular pressing (ECAP) have many limitations, e.g. no freedom in shaping a complex geometry of the product, risk of chip ignition during machining, and ageing process which significantly worsens mechanical properties
Summary
Over 80% of all innovations in the aerospace industry owe their existence to the use of new materials and new technologies [1]. Weight reduction is the easiest and most cost-effective option that necessities the search for new, lighter, and high-strength construction materials and new manufacturing technologies [4]. Composites, and light metallic alloys are materials that meet these requirements. Magnesium and magnesium alloys are one of the lightest metallic materials. Their low density of 1.73 g/cm and the resulting high specific strength make them a perfect alternative to slightly heavier aluminium alloys. The use of light alloys in aviation will result in reduced aircraft weight, which in turn means reduced fuel consumption as well as combustion product emission to the atmosphere. As early as in the 1940s and 1950s, researchers saw the advantages of using magnesium alloys in aviation and identified new
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