Study of the Mechanical Behavior of Topologically Optimized Arc Wire Direct Energy Deposition Aerospace Fixtures
Source abstract
Abstract
The reliability and performance qualification of additively manufactured metal parts is essential for their successful and safe use in engineering applications. Additive Manufacturing (AM) allows parts to be produced more easily than traditional manufacturing. Arc Wire Direct Energy Deposition (AW-DED) is one of the lesser-known metal additive manufacturing technologies. It has enormous potential for large-scale 3D printing applications in the aerospace industry. However, in the aerospace industry, one of the main challenges today is to reduce the weight of components without compromising their structural functionality. Topology optimization offers design engineers the opportunity to create lightweight and complex structural parts. In arc wire direct energy deposition (AW-DED) processes, processing parameters affect material microstructure features, overall part quality, and integrity, as well as bulk mechanical behavior. To address such challenges, the investigation presented in this paper describes a novel digital design approach combining topology optimization, process simulations, and size optimization of the tool components used in the aerospace industry to address effects caused during manufacturing by using Finite Element Modeling (FEM) simulations. This can lead to reduced costs, development time, material consumption, and product weight. Due to the flexibility mentioned above, parts designed for AM have the same structural load as conventional parts but with reduced mass and better part design. The results of this application are discussed in depth in this paper. This is a new research work with useful results and conclusions in the methodology for the evaluation of mechanical behavior of topologically optimized metal additive manufactured components. For this purpose, aerospace fixtures have been topologically designed by means of AW-DED-process-oriented techniques. Aerospace fixtures are normally used in the aerospace industry to support and hold various components. These new design paradigms make it possible to save on material costs oriented toward more sustainable and flexible manufacturing. ELKARTEK 2020 KK-2020/00042, ZL-2021/00989
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Additive Manufacturing Materials and Processes · Manufacturing Process and Optimization
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (35)
Show source-provided references
1. B. Blakey-Milner, P. Gradl, G. Snedden, M. Brooks, J. Pitot, E. Lopez, M. Leary, F. Berto and A. du Plessis, Metal Additive Manufacturing in Aerospace: A Review, Mater. Des., 2021, 209, 110008. https://doi.org/10.1016/j.matdes.2021.11000810.1016/j.matdes.2021.110008 ↗
2. E. Hosseini and V.A. Popovich, A Review of Mechanical Properties of Additively Manufactured Inconel 718, Addit. Manuf., 2019, 30, 100877. https://doi.org/10.1016/j.addma.2019.10087710.1016/j.addma.2019.100877 ↗
3. D. Ding, Z. Pan, D. Cuiuri and H. Li, A Multi-bead Overlapping Model for Robotic Wire and Arc Additive Manufacturing (WAAM ), Robot. Comput. Integrat. Manuf., 2015, 31, p 101–110. https://doi.org/10.1016/j.rcim.2014.08.00810.1016/j.rcim.2014.08.008 ↗
4. S.C. Altıparmak and B. Xiao, A Market Assessment of Additive Manufacturing Potential for the Aerospace Industry, J. Manuf. Process., 2021, 68, p 728–738. https://doi.org/10.1016/j.jmapro.2021.05.07210.1016/j.jmapro.2021.05.072 ↗
5. S.A.M. Tofail, E.P. Koumoulos, A. Bandyopadhyay, S. Bose, L. O’Donoghue and C. Charitidis, Additive Manufacturing: Scientific and Technological Challenges, Market Uptake and Opportunities, Mater. Today, 2018, 21(1), p 22–37. https://doi.org/10.1016/j.mattod.2017.07.00110.1016/j.mattod.2017.07.001 ↗
6. C.R. Cunningham, J.M. Flynn, A. Shokrani, V. Dhokia and S.T. Newman, Invited Review Article: Strategies and Processes for High Quality Wire Arc Additive Manufacturing, Addit. Manuf., 2018, 22, p 672–686. https://doi.org/10.1016/j.addma.2018.06.02010.1016/j.addma.2018.06.020 ↗
7. S.W. Williams, F. Martina, A.C. Addison, J. Ding, G. Pardal and P. Colegrove, Wire + Arc Additive Manufacturing, Mater. Sci. Technol., 2016, 32, p 641–647. https://doi.org/10.1179/1743284715Y.000000007310.1179/1743284715Y.0000000073 ↗
8. D. Yili, Y. Shengfu, S. Yusheng, H. Tianying and Z. Lichao, Wire and Arc Additive Manufacture of High-Building Multi-Directional Pipe Joint, Int. J. Adv. Manuf. Technol., 2018, 96, p 2389–2396. https://doi.org/10.1007/s00170-018-1742-210.1007/s00170-018-1742-2 ↗
9. W. Ya, K. Hamilton, On-Demand Spare Parts for the Marine Industry with Directed Energy Deposition: Propeller Use Case, Industrializing Additive Manufacturing - Proceedings of Additive Manufacturing in Products and Applications - AMPA2017. 4 (2018) https://doi.org/10.1007/978-3-319-66866-6.10.1007/978-3-319-66866-6 ↗
10. R. Ponche, O. Kerbrat, P. Mognol and J.Y. Hascoet, A Novel Methodology of Design for Additive Manufacturing Applied to Additive Laser Manufacturing Process, Robot. Comput.-Integrat. Manuf., 2014, 30, p 389–398. https://doi.org/10.1016/j.rcim.2013.12.00110.1016/j.rcim.2013.12.001 ↗
11. F. Veiga, A. Suárez, E. Aldalur, I. Goenaga, J. Amondarain, Wire Arc Additive Manufacturing Process for Topologically Optimized Aeronautical Fixtures, 3D Printing and Additive Manufacturing. (2021).10.1089/3dp.2021.0008 ↗
12. C. Wang, J. Zhu, M. Wu, J. Hou, H. Zhou, L. Meng, C. LI and W. Zhang, Multi-Scale Design and Optimization for Solid-Lattice Hybrid Structures and their Application to Aerospace Vehicle Components, Chinese J. Aeronaut., 2021, 34, p 386–398.
13. A. Dagkolu, I. Gokdag and O. Yilmaz, Design and Additive Manufacturing of a Fatigue-Critical Aerospace Part Using Topology Optimization and L-PBF Process, Procedia Manuf., 2021, 54, p 238–243. https://doi.org/10.1016/j.promfg.2021.07.03710.1016/j.promfg.2021.07.037 ↗
14. J.D. López-Castro, A. Marchal, L. González and J. Bontana, Topologcal Optimization and Manufacturing by Direct Metal Laser Sintering of an aeronautizal Part in 15–5PH Stainless Steel, Procedia Manuf., 2017, 13, p 818–824. https://doi.org/10.1016/j.promfg.2017.09.12110.1016/j.promfg.2017.09.121 ↗
15. J. Zhu, H. Zhou, C. Wang, L. Zhou, S. Yuan and W. Zhang, A Review of Topology Optimization for Additive Manufacturing: Status and Challenges, Chin. J. Aeronaut., 2021, 34, p 91–110. https://doi.org/10.1016/j.cja.2020.09.02010.1016/j.cja.2020.09.020 ↗
16. General Electric, GE Global Research, 3D Printing New Parts for Aircraft Engines, 2017, (2018). https:// www.geglobalresearch.com/blog/3d-printing-creates-new-parts-aircraft-engines.
17. C. Greer, A. Nycz, M. Noakes, B. Richardson, B. Post, T. Kurfess and L. Love, Introduction to the Design Rules for Metal Big Area Additive Manufacturing, Addit. Manuf., 2019, 27, p 159–166. https://doi.org/10.1016/j.addma.2019.02.01610.1016/j.addma.2019.02.016 ↗
18. F. Michel, H. Lockett, J. Ding, F. Martina, G. Marinelli and S. Williams, A Modular Path Planning Solution for Wire + Arc Additive Manufacturing, Robot. Comput.-Integrat. Manuf., 2019, 60, p 1–11. https://doi.org/10.1016/j.rcim.2019.05.00910.1016/j.rcim.2019.05.009 ↗
19. D. Jafari, T.H.J. Vaneker and I. Gibson, Wire and Arc Additive Manufacturing: Opportunities and Challenges to Control the Quality and Accuracy of Manufactured Parts, Mater. Des., 2021, 202, 109471. https://doi.org/10.1016/j.matdes.2021.10947110.1016/j.matdes.2021.109471 ↗
20. S. Li, L.J. Zhang, J. Ning, X. Wang, G.F. Zhang, J.X. Zhang, S.J. Na and B. Fatemeh, Comparative Study on the Microstructures and Properties of wire+arc Additively Manufactured 5356 Aluminium Alloy with Argon and Nitrogen as the Shielding Gas, Addit. Manuf., 2020, 34, 101206. https://doi.org/10.1016/j.addma.2020.10120610.1016/j.addma.2020.101206 ↗
21. M. Dinovitzer, X. Chen, J. Laliberte, X. Huang and H. Frei, Effect of Wire and Arc Additive Manufacturing (WAAM) Process Parameters on Bead Geometry and Microstructure, Addit. Manuf., 2019, 26, p 138–146. https://doi.org/10.1016/j.addma.2018.12.01310.1016/j.addma.2018.12.013 ↗
22. E. Aldalur, F. Veiga, A. Suárez, J. Bilbao and A. Lamikiz, Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel, Metals, 2020, 10, p 892. https://doi.org/10.3390/met100708910.3390/met1007089 ↗
23. Normalización Española, Materiales Metálicos. Ensayo de tracción. Parte 1: Método de ensayo a temperatura ambiente, UNE-EN ISO 6892- 1, February 2017
24. T. Artaza, A. Suárez, F. Veiga, I. Braceras, I. Tabernero, O. Larrañaga et al., Wire Arc Additive Manufacturing Ti6Al4V Aeronautical Parts Using Plasma Arc Welding: Analysis of Heat-Treatment Processes in Different Atmospheres, J Mater Res Technol, 2020, 9(6), p 15454–15466.10.1016/j.jmrt.2020.11.012 ↗
25. M. Köhler, S. Fiebig, J. Hensel and K. Dilger, Wire and Arc Additive Manufacturing of Aluminum Components, Metals, 2019, 9, p 1–9. https://doi.org/10.3390/met905060810.3390/met9050608 ↗
26. A.S. Haselhuhn, M.W. Buhr, B. Wijnen, P.G. Sanders and J.M. Pearce, Structure-Property Relationships of Common aluminum Weld Alloys Utilized as Feedstock for GMAW-based 3-D Metal Printing, Mater Sci Eng A, 2016, 673, p 511–523.10.1016/j.msea.2016.07.099 ↗
27. M. Rafieazad, M. Ghaffari, A. VahediNemani et al., Microstructural Evolution and Mechanical Properties of a Low-Carbon Low-Alloy Steel Produced by Wire Arc Additive Manufacturing, Int J Adv Manuf Technol, 2019, 105, p 2121–2134. https://doi.org/10.1007/s00170-019-04393-810.1007/s00170-019-04393-8 ↗
28. E.M. Perez-Soriano, E. Ariza, C. Arevalo, I. Montealegre-Melendez, M. Kitzmantel and E. Neubauer, Processing by Additive Manufacturing Based on Plasma Transferred Arc of Hastelloy in Air and Argon Atmosphere, Metals., 2020, 10(2), p 200. https://doi.org/10.3390/met1002020010.3390/met10020200 ↗
29. C.E. Seow, H.E. Coules, G. Wu, R.H.U. Khan, X. Xu and S. Williams, Wire + Arc Additively Manufactured Inconel 718: Effect of post- deposition heat treatments on microstructure and tensile properties, Mater. Des., 2019, 183, 108157. https://doi.org/10.1016/j.matdes.2019.10815710.1016/j.matdes.2019.108157 ↗
30. H. Chen, B. Tan, C. Song and J. XFeng, Microstructure Evolution and Mechanical Properties of Laser Metal Deposition of Invar 36 Alloy, Optics & Laser Technol., 2020, 125, 106037.10.1016/j.optlastec.2019.106037 ↗
31. X. Chen, J. Li, X. Cheng, B. He, H. Wang and Z. Huang, Microstructure and Mechanical Properties of the Austenitic Stainless Steel 316L Fabricated by Gas Metal Arc Additive Manufacturing, Mater. Sci. Eng., A, 2017, 703, p 567–577. https://doi.org/10.1016/j.msea.2017.05.02410.1016/j.msea.2017.05.024 ↗
32. F. Wang, S. Williams, P. Colegrove and A.A. Antonysamy, Microstructure and Mechanical Properties of Wire and Arc Additive Manufactured Ti-6Al-4V, Metall. and Mater. Trans. A., 2013, 44A, p 968–977. https://doi.org/10.1007/s11661-012-1444-610.1007/s11661-012-1444-6 ↗
33. J. Plangger, P. Schabhüttl, T. Vuherer and N. Enzinger, CMT Additive Manufacturing of a High Strength Steel Alloy for Application in Crane Construction, Metals., 2019, 9(6), p 650. https://doi.org/10.3390/met906065010.3390/met9060650 ↗
34. http://www.matweb.com [Accessed 22 July 2021]
35. T. Bhujangrao, F. Veiga, A. Suárez, E. Iriondo and F.G. Mata, High-Temperature Mechanical Properties of IN718 Alloy: Comparison of Additive Manufactured and Wrought Samples, Curr. Comput.-Aided Drug Des., 2020, 10(8), p 689. https://doi.org/10.3390/cryst1008068910.3390/cryst10080689 ↗