Additive Manufacturing of Aerospace Alloys for Aircraft Structures

摘要

The Materials & Manufacturing Directorate of the Air Force Research Laboratory (AFRL/ML) has been actively involved in R&D activities associated with fusion-based additive manufacturing (AM) of aerospace alloys since the late 1990's. The primary focus of these activities has been the use of AeroMet's LAM(SM) (laser additive manufacturing) process to produce Ti-6Al-4V structures. Many similar processes are under development elsewhere, including electron-beam-, plasma-transferred-arc-, and conventional welding-based AM processes. Many of the lessons learned during the development of LAM(SM) are directly applicable to these related processes. A key portion of the AFRL/ML LAM(SM) effort was the formation of a multi-disciplinary team to identify potential applications, technical gaps, and barriers to implementation. This team worked closely with various DoD and contractor organizations to develop and execute a roadmap for transitioning LAM(SM) into production of flight- qualified aircraft hardware. A review of the evolution of LAM(SM) from laboratory to production is presented with a focus on the unique aspects of LAM(SM) as compared to more conventional product forms. The challenges of developing and qualifying AM processes for aerospace use are also highlighted.