Beruflich Dokumente
Kultur Dokumente
DOI:10.21884/IJMTER.2017.4288.H0FCA 120
International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 04, Issue 9, [September– 2017] ISSN (Online):2349–9745; ISSN (Print):2393-8161
Mn and Zr formulated. This synergic effect highlights the light weight characteristics along with
high corrosion resistance and mechanical properties.Today Space X –Falcon 9 incorporates the
advanced properties of this alloy for manufacturing its two stage reusable rockets. The Airbus
implements a considerable amount of Aluminium-Lithium for the development of wings and
fuselage. The Al-Li alloys have superior fatigue crack growth performance. The Airbus A380
airliner uses GLARE composites- “GLASS-Reinforced” Fiber Metal Laminate (FML).
The Boeing 787 Dreamliner uses specific composites along with combinations of metals and
it alloys. Boeing787- Composites are also used extensively in both expendable launch vehicle and
satellite structure.
II. WHY ADDITIVE MANUFACTURING?
Additive manufacturing also called as “3D printing” or “Rapid prototyping” is the process of
synthesizing three dimensional objects by adding materials successively with a help of computer-
aided design model. Additive Manufacturing is being used for the production of series of
components for the most demanding applications [1]. The use of additive manufacturing technology
is developing in many industries: Aerospace engineering, Medical, Dental applications, Automotive
and transportation etc. [2].
The advantages of using this technique over conventional methods are increased design
freedom, structures that are light weight, near-net shape capability, production time being very less,
environment sustainability and economic low volume production.
AM processes are divided into 7 groups: 1. Material extrusion, 2. Material jetting, 3. Binder
jetting, 4. Sheet lamination, 5. Vat photo polymerization, 6. Powder bed fusion and 7. Direct energy
deposition.
The three principle involved in the additive manufacturing technique are: Modeling, Printing
and Finishing. In modeling, 3D models are created using computer-aided software via a scanner. The
scanner looks for information regarding the shape and the appearance of real object and then creates
State of Layer
Material
starting Process creation Typical materials Applications
preparation
material method
Continuous
Melted in Thermoplastics, Prototypes, Casting
FDM extrusion &
nozzle waxes patterns
Filament deposition
Robo- Paste in Continuous
Ceramic paste Functional parts
casting nozzle extrusion
Laser Prototypes, castng
SLA Resin in vat UV curable resin
scanning patterns
Liquid
Polymer in Ink-Jet Acrylic plastics, Prototypes, casting
MJM
jet printing wax patterns
Thermoplastics,
Prototypes, casting
Powder in Laser waxes, Metal
SLS patterns, Metal and
bed Scanning powder, ceramics
ceramic
powder
Powder in Laser Tooling, Functional
SLM Metal
Powder bed scanning parts
Powder in Electron beam Tooling, Functional
EBM Metal
bed scanning parts
Drop-on- Polymer, Metal,
Powder in Prototypes, Casting
3DP demand binder ceramic, other
bed shells, Tooling
printing powders
Feeding and
Solid Laser binding of Paper, Plastic, Prototypes, Casting
LOM
Sheet Cutting sheets with Metal Models
adhesives
III. METAL ALLOYS USING ADDITIVE MANUFACTURING
The metal alloys are chosen because they satisfy the standards of quality, resistant to
corrosion, lightweight, excellent physical and chemical properties. These alloys have the primary
elements as Aluminium, Titanium, Stainless steel and Nickel.
3.1. Aluminium alloys: Aluminium was first put into use in 1903, when wright brothers developed
an engine with a light weight Aluminium engine block. In 1930, the demand for Aluminium became
meteoric. Its unique characteristics of being a light weight metal, high strength and high workability
make it a potential material for aerospace industry. Today, there are over 27,000 commercial aircraft
flying in the world and many thousands of light aircraft and helicopters. The fuselage, seats and
internal fittings are made using Al, for light weight and reducing payload purposes. Currently
material property enhancement technique such as Additive Manufacturing is used to develop the
same parts/tools (as the conventional methods) for aerospace industry with better material property.
3.1.1. Aluminium 7075: Al7075 being the primary alloy, its properties were tested after being
additively manufactured. Reschetnik et al. [5] investigated the fatigue crack behaviour & mechanical
property of Additively manufactured, EN AW 7075 Al alloy. SLM process was used to process the
manufacturing of Al7075 and some of the manufacturing specimens were subjected to heat
treatment. The fatigue crack growth remained same for both the heat treated and those which weren‟t
and the mechanical property remained lower than conventionally produced ones. Now, changing the
alloy composition lead to favourable results. Maria L. Montero Sistiaga et al. [6] have conducted the
experiment by the addition of Si into Al7075. Si was added under different compositions. The effect
3.1.2. Aluminium AlSi10Mg: It comprises of Aluminium alloy with 10%Si along with minor
amount of Mg, Fe and other elements. The material is characterised by a very high hardness,
corrosion resistance, low density (good for light weight components), high stability and high specific
strength (strength to mass ratio). The presence of silicon makes the alloy both harder and stronger
than pure aluminium due to the formation of Mg2Si precipitate. Due to the high cooling rates during
the construction process, the mechanical properties of the additively manufactured components are
better than the corresponding casting process . The production of these components is done by
Selective Laser Melting (SLM). The components show a homogeneous and almost pore-free
structure. Selective laser melting process is carried out on the alloy with the process parameters
(Power = 400W, layer thickness 25µm) following which heat treatment is carried on. It is plausible
to modify the mechanical properties of the manufactured components by applying T6 heat treatment
and elongation can be improved. Further, the anisotropic properties are reduced as result of the
layered structure. It is used in Aircraft and Space applications.The Mechanical property of additively
manufactures AlSi10Mg components is shown in Table 3 [9].
Table 3. Mechanical properties of Additively manufactured AlSi10Mg component [9]
MECHANICAL PROPERTIES OF AM COMPONENTS
As Built Stress relieved (note 2*)
Tensile Strength (UTS) (note 1*)
Horizontal direction (XY) 442 MPa ± 6 MPa 334 MPa ± 1Mpa
Vertical direction (Z) 417 MPa ± 27 MPa 339 MPa ± 6 Mpa
Yield Strength (note 3*)
Horizontal direction (XY) 264 MPa± 2 MPa 211 MPa ± 2Mpa
Vertical direction (Z) 206 MPa ± 6 MPa 174MPa ± 4Mpa
Elongation at break (note 3*)
Horizontal direction (XY) 9% ± 1% 9% 2%
Vertical direction (Z) 6% ± 2% 4% 1%
Modulus of elasticity (note 3*)
Horizontal direction (XY) 71 GPa ± 5 GPa 71 GPa ± 2 Gpa
Vertical direction (Z) 68 GPa ± 2 GPa 66 GPa ±3 Gpa
Hardness (Vickers) (note 4*)
3.4. Stainless Steel 1.4542: Stainless steel when processed through additive manufacturing results in
high strength. The material is corrosion resistant and has excellent ductility. This material possesses
some good mechanical properties. The tensile strength has a range of 930MPa, but when heat treated
it can go up to 1040-1100MPa. However there is no significant change in yield stress (450MPa)
when heat treated and when not heat treated [20].
3.5. Titanium alloys: The first application of Titanium began early in the 1950‟s and since then
demand increased. The titanium satisfies all the required aircraft material properties. It has high
corrosion resistance and excellent strength to weight ratio. Most of the titanium produced assist in
the development of the aircraft engine. Titanium occupies the disk, blades, shafts, and casing of the
aircraft engine. They are capable of operating at sub-zero conditions
till600ºC[21].Currently, titanium makes up to 10% of empty weight of aircraft
such as the Boeing 777. It has high strength up to 1200MPa. Titanium alloys with its application and
attributes are listed in the Table 6. Ikuhiro Inagaki et al. (2014) discussed the property and
applications of Ti alloys in aerospace industries [22].
3.5.1. Ti6Al4V: Eckart Uhlmann et al. [23] investigated the properties of additively manufactured
Titanium alloy for aircraft components. The additive process is carried out by using SLM technique.
The metal powder of TiAl64V is prepared and percentage composition tests are carried out on the
metal powder, after which additive manufacturing process is carried out. An inert gas (Ar)
environment is setup in the experiment to avoid oxidation phenomenon . The layer thickness during
the process is maintained at 50µm.Post processing is done on the culmination stage of the product
and results are compared with similar products at different experimental conditions.
In the pre-processing stages, The chemical composition of the powder is checked using a
chemical composition testing unit: SEM LEP 1455VP,which uses energy dispersive X-rays ,
analysed using SEM [23].One more parameter that is measures is the packed filling density. As
packing density increases, the blow holes decreases, The tests results show that with packed filling
density of 53%, the raw material has a density of 4.43g/cm3 [24].
The additive manufacturing process is carried using SLM technique and post processing
activities are done on the specimen [25]: 1. Thermal post processing is carried out for reducing high
residual stress and close micro cracks [26, 27], 2. Hot isostatic pressing is carried out after the
thermal post processing. Hot isostatic pressing is used to reduce micro blowholes through annealing
at high temperature, It also reduces porosity, increases density, improves fatigue property, increases
elongation [27]. Apart from mechanical properties, other properties are also tested. 3. Density is
calculated using Archimedes principle. The results obtained show a value of 4.35g/cm3 [28, 29] 4.
Micro hardness is determined along XY as 316H30 and along XZ as 320H30 [30, 31].
IV. METAL MATRIX COMPOSITES USING ADDITIVE MANUFACTURING
Critical spacecraft missions involving dynamic and thermal disturbances require spacecraft
structures to be of high pointing accuracy and dimensional stability. Composite materials with their
high specific stiffness, light weight characteristics and low coefficient of thermal expansion, prove to
be an essential contributor for this purpose. The continuous-fiber reinforced MMC was first used in
tubular struts. It is used as frame and rib truss members in the mid-fuselage section and also for the
landing gear drag link of the space shuttle orbiter[32,33].Therefore, the development of MMCs was
primarily directed toward diffusion-bonding processing[34].Metal matrix imparts ductility and
thermal stability for the composites whereas the fiber increases strength and stiffness, also enhances
the resistance to creep. The most commonly used MMC‟s are Aluminium and its alloy such as
Copper, Titanium and Magnesium. MMC can be categorized based on type of reinforcements- fibre
or particulate. Powder metallurgy, squeeze casting, spray deposition are the most common
fabrication processes of MMC‟s. The constitutive models of the NiTi element and Al matrix have
investigated average interface shear strength of 7.28 MPa and an effective coefficient of thermal
expansion of zero at 135ºC. Ultrasonic additive manufacturing uses ultrasonic metal welding to
develop aluminium matrix composites [35,36].This composite comprises of aluminium matrices and
embedded shape memory NiTi magnetostricitve, Galfenol and electro-active phases (Polyvinylidene
fluoride phases). Advantage of this technique is that the working temperature is low as 25ºC during
Figure 3. Typical tensile Strain-Stress curves for specimens with different carbon fiber contents (carbon fiber
length is 150µm) [41]
Figure 4. Typical Stress-Strain curves for the effects of carbon fiber length (carbon fiber content is 5wt%) [41]
Flexural property changes were also observed. It was seen that adding 5%weight of carbon
fibre improved all the flexural property except flexural yield strength. With 5% carbon fibre content,
the flexural stress, flexural modulus and flexural toughness of carbon fibre reinforced polymer
composite specimen were increased by 11.82%, 16.82%, 21.86% respectively, as compared with
pure plastic specimen. The flexural stress-strain properties obtained are shown in Figure 5 [41].
Figure 7. Effect of fiber content and preparation process on tensile strength and modulus of ABS/CF
composites[45]
Ryosuke matsuzaki et al. [46] conducted a test on thermoplastic composite (polylactic acid)
reinforced with carbon fibre by fused deposition modeling (FDM). They came to conclusion that
those reinforced with unidirectional carbon fibre showed mechanical properties superior to those
unreinforced thermoplastic. Also continuous fibre reinforcement improved tensile strength of printed
composite relative to the values shown by conventional 3D printed polymer matrix composite.
Figure 8. Schematic diagram of extrusion/deposition based additive manufacturing process and hypothesis of
glass-fiber alignment [47]
was used. Tensile strength measurement was carried out using same TA500 texture analysis
for both the methods of manufacturing (additive manufacturing and conventional method). Both the
tensile and flexural data‟s were calculated. It was concluded that there was improved mechanical
properties in printed samples compared to Non-printed samples manufactured. The reason is being
due to the densification in case of printed samples (additive manufacturing) as it is extruded through
nozzle and of the fibre alignment in the sample. Also it has been observed that when glass fibre was
added, there was an increase in tensile strength of printed samples by 30% when compared to when
glass fibre is absent in the sample. The schematic diagram of extrusion based additive manufacturing
Figure 9. Comparison of mechanical properties of printed and non-printed products (a) flexural and (b) tensile
Stress-Strain curves for urea formaldehyde-wood flour only (c) flexural and (d) tensile Stress-Strain curves for
urea formaldehyde-wood flour-glass fiber samples [47]
5.3.Aramid Fibre Reinforced composites: These are the fibre which are formed from aromatic
polyamides. They have high strength and high modulus. They are introduced in the early 1970‟s.
Most common aramid materials are kevlar and nomex. They have the advantage of having good
impact resistance and good elongation. Their application finds in the helicopter blades. They are
mainly used for components that are subjected to high stresses. For example, they are needed for the
construction of gliders. When compared to carbon fibre reinforced plastics, they have lower
compression resistance. However, they have higher impact resistance. Due to this reason they are
used very often as safety shields for engine cowls. Lot of research work is being carried out on
additive manufacturing of composites reinforced with aramid fibre for their application in aerospace
engineering [53].
VI. CERAMIC MATRIX COMPOSITES USING ADDITIVE MANUFACTURING
These are the composites in which the particulates, fibres or whiskers of one ceramic material
are embedded into the matrix of another ceramic. They are reinforced with fibres that add
mechanical strength. In these composites, mechanical stresses are transferred from weaker matrix to
strong internal fibres where forces are dispersed and mitigated through bulk of the composite. They
are also added with one or more additional property modifying components like SiC or Zirconia to
modify the surface and bulk properties. These composites may be fabricated by hot pressing, hot
isostatic pressing and liquid phase sintering techniques.However, the fabrication of ceramic matrix
composites by conventional techniques is difficult. But additive manufacturing (AM) technique has
ability to deal with those type of materials without need for molds or part specific tools. This ceramic
matrix composites by additive manufacturing are produced by either Selective Laser Sintering (SLS),