Light Weight Materials. Группа авторов

of materials, thereby reducing the cost of production. AM contributes its foremost capability to serving the aerospace industry, because this industry faced a great challenge to reduce the weight and size of components in order to avoid dangers and promote safety and durability. Designing and manufacturing flight-worthy components from high-performance materials are needed for commercial and military aerospace platforms, which can be achieved by AM. 3D printing (3DP) offers multifaceted, amalgamated parts with extraordinary strength. The involvement of less material and consolidated designs results in the overall reduction in weight, which acts as the most important factor in manufacturing for aerospace (Russell 2019). AM is often used for aerodynamic analysis, which has acute prominence for aerospace. The selective laser melting and binder jetting are used to create strong-featured, plane scale prototypes of aerospace designs to yield exact models that allow design indentation and feasibility. 3DP is generally used to produce structural, low-volume metal supports (with DMSL/SLM), which have intricate lifesaving systems, for the internal barricade of a plane. The extremely appropriate technique of prototyping is also ultimate for aerodynamic test results and analysis, as the stable surface finish factor is able to meet the appropriate final part through the 3DP technology. AM has an extraordinary degree of design freedom that assists in optimizing the parts and incorporating multiple features in a single component (Kamal 2019). AM greatly supports the aerospace industry as it is mainly focused on components with multifarious competence and low volume production. The assembly of composite designs with various sizes and the scope that prevails manufacturing in the required volume are achieved in a single machine through AM.

Figure 1.9. Aerospace components fabricated through AM (Hiemenz 2014)

1.6. Challenges faced in the aerospace industry

One of the biggest challenges faced in the aerospace industry is the inability to manufacture large and odd-sized components. Another main challenge faced in the field of aerospace is that the strength in the plane of layers is not uniform. The scalability of traditional manufacturing methods is limited, which find difficulty in stocking inventories. Printing multiple materials cannot be achieved simultaneously with AM, thus making it somewhat unsatisfactory. This is a problem that needs to be solved with advances in material science, by expanding the selection of materials and reducing their cost.

1.7. Overcoming aerospace challenges with AM

      AM in aerospace gives a good inspection of the parts in a completely automated process. In the manufactured parts in aerospace, an accuracy of about 30–40 microns is offered by AM. Good quality parts along with good tolerance levels of less than 10 microns can be achieved with AM. The flexibility of AM allows the designers to manufacture various parts using different materials, thus increasing its competitiveness. Production and unloading can occur simultaneously with AM technology incorporated in the aerospace industry to overcome the scalability criteria.

1.8. Future work

      This chapter explained in detail an appraisal of the methodologies and suitable materials used in AM for advancing the aerospace industry with the performances of topological and material optimization, design integration and part consolidation that promotes profitable quantity and quality products:

       – The progression and characteristics of AM technology were studied, along with the impact of material properties and processing operations such as orientation and part performance relevant to specific user-defined part design, which should be developed to enhance the shape and structure of alloyed elements.

       – The different new materials with varying mechanical and metallurgical properties should be examined to find a better strength-to-weight ratio than the existing alloys.

       – AM acts as a single-step process to fabricate multifaceted components; hence, simulation and analysis of AM parts should be carried out to avoid and investigate errors in the design of the component and its failure to prevent wastage of materials.

1.9. Conclusion

      AM is a versatile technology. Today, it has become the central building block of future hybrid manufacturing. The additive manufactured components are efficiently used in aerospace, automobile and biomedical industries.

       – Today, Industry 4.0 is progressing towards smart manufacturing methodologies where AM has emerged as popular and globally disruptive for the engineering industry.

       – When compared to other industries, aerospace is the vibrant area that demands higher volume production of lightweight multifaceted components with high strength and long-term durability.

       – The aerospace industry has been prospering in additively manufacturing spacecraft components with multi-functioning capability of complex user-defined geometries in minimal weight.

       – The main advantage of AM is that it reduces the wastage of materials as well as fabrication time and provides high quality components. The overall weight of an aircraft reduces fuel consumption.

       – AM acts as a dynamic and feasible technology with no boundaries for manufacturing modern machineries, especially in aerospace, for developing new components and modifying the existing geometries to generate newly designed aircraft structures.

1.10. References

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      Anderl, R. (2014). Industrie 4.0-advanced engineering of smart products and smart production. Proceedings of International Seminar on High Technology.

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      Brandsmeier, W., Calvert, M., Greene, S., O’Neal, D., Protz, C., Richard, J., and Morgan, K. (2017). Additive manufacturing overview: Propulsion applications, design for and lessons learned. Defense Manufacturing Conference, NASA, December.

      DebRoy, T., Wei, H.L., Zuback, J.S., Mukherjee, T., Elmer, J.W., Milewski, J.O., Beese, A.M., Wilson-Heid, A., De, A., and Zhang, W. (2018). Additive manufacturing of metallic components–process, structure and properties. Progress in Materials Science, 92, 112–224.

      Devadiga, N.M. (2017). Tailoring architecture centric design method with rapid prototyping. 2nd International Conference on Communication and Electronics Systems (ICCES), pp. 924–930.

      Eisenbarth, D., Soffel, F., and Wegener, K. (2019). Effects of direct metal deposition combined with intermediate and final milling on part distortion. Virtual and Physical Prototyping, 14(2), 130–134.

      Garmendia, I., Pujana, J., Lamikiz, A., Madarieta, M., and Leunda, J. (2019). Structured light-based height control for Laser Metal Deposition. Journal of Manufacturing Processes, 42, 20–27.

      Gokuldoss, P.K., Kolla, S., and Eckert, J. (2017). Additive manufacturing processes: Selective laser melting, electron beam melting and binder jetting – Selection guidelines. Materials, 10(6), 672.

      Herzog, D., Seyda, V., Wycisk, E., and Emmelmann, C. (2016). Additive manufacturing of metals. Acta Materialia, 117, 371–392.

      Hiemenz, J. (2014). Additive Manufacturing Trends in Aerospace. Stratasys Ltd.

      Imam, M.A., Rock, B.Y., Rowland, R., Zarah, T.F., and Akhtar, K. (2016). Consolidation of cristal metals