РROSPECTS FOR THE APPLICATION OF ADDITIVE TECHNOLOGIES IN AIRCRAFT AND ROCKET ENGINEERING

Сергей Викторович Аджамский, Анна Андреевна Кононенко, Ростислав Вячеславович Подольский

Abstract


SLM technology is an innovative production of products of complex geometric shapes through layer-by-layer material building-up based on a computer-based CAD model using special 3D printers. With the help of SLM technology, they create precise metal products for work as part of components and assemblies for critical purposes (for example, aerospace). SLM successfully replaces traditional manufacturing methods, since products built using SLM technology often surpass the properties of products made using traditional technologies.

This technology has several advantages for the application and manufacture of aerospace products: the possible production of thin-walled parts, simplifying their production, by reducing the number of technological transitions, using computer programs and automation tools to optimize the product design, which opens up the possibility of reducing the weight of aircraft structural elements apparatuses.

One of the opportunities that SLM technology allows to realize is the replacement of solid metal elements with openwork structures, ensuring a sufficient level of mechanical properties. The use of openwork designs and topological optimization can make it possible to lighten a part up to 50 %. However, it is important to ensure the necessary level of mechanical properties due to the reasonable design of elements: mesh thickness, cell size, and shape, etc. Besides, in aircraft and rocket science, often additive technologies are used to create products with internal channels of thin-walled products with inclined surfaces. Therefore, it is important to ensure the quality of thin-walled surfaces with different angles of inclination.

Printing was carried out on a 3-D Alfa-150 printer manufactured by ALT Ukraine LLC. As part of the experiment, samples were made in the form of a cube with the internal structure of the honeycomb and a solid cube with equal dimensions in different modes. The second group of samples in the form of plates with different angles of inclination relative to the Z-axis (0°, 30°, 45°).

When practicing printing modes with internal thin structures, it was found that under adverse conditions, fusion conditions were created, the metal fell through on a layer of powder, overhanging elements formed, and the lower surface with high roughness. Under favorable conditions, the lower surface is smooth, the layers are clearly defined, correspond to the given geometry of the model. An experiment was also performed to test the printing modes of flat samples with different angles of inclination. It has been established that different modes are optimal for different tilt angles. Thus, it was found that SLM technology allows you to create thin-section elements with maximum accuracy, and to produce parts with a unique geometric structure. According to the developed process parameters, parts of complex shape for operation in aerospace engineering can be created.

Keywords


SLM technology; Inconel 718; openwork design; topological optimization; weight reduction; aircraft

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DOI: https://doi.org/10.32620/aktt.2020.7.09

Copyright (c) 2020 Сергей Викторович Аджамский, Анна Андреевна Кононенко, Ростислав Вячеславович Подольский