Browse Topic: Additive manufacturing

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Composite Secondary and Tertiary Structure for Landing Gear AIR6827 (Current)11/26/2025
This document will contain guidance and considerations for the use of composite materials on non-primary structure for landing gear systems. Content to include design considerations, conditions and applications where composites are feasible/beneficial, high-level descriptions of various manufacturing processes, and certification/validation considerations.
A-5B Gears, Struts and Couplings CommitteeNEW
Development and Qualification of Composite Landing GearsAIR5552A (Current)11/26/2025
This information report provides general guidance for the design considerations, qualification in endurance, strength and fatigue of landing gear using composite components as principle structural elements. The information discussed herein includes the development and evaluation of design data considering: the potential for imbedded manufacturing defects, manufacturing process variations, the component operating environment, potential damage threats in service, rework and overhaul, and inspection processes. This AIR mainly discusses the use of thick composites for landing gear structural components. Considerations and recommendations provided in this AIR may therefore differ greatly from considerations and recommendations found in widely accepted composite design references such as CMH-17 and Advisory Circulars such as AC 20-107(B).
A-5B Gears, Struts and Couplings CommitteeNEW
Advancing Helicopter Repair: Gamma's Innovative Materials for the U.S. ArmyF-0081-2025-03475/20/2025
Maintaining the operational readiness of military helicopters demands repair solutions that are fast, reliable, and adaptable. This paper presents the integration of Gamma Alloys' advanced metal matrix composites (MMCs) into additive manufacturing (AM) techniques - specifically Cold Spray and Friction Stir Additive Manufacturing (FSAM) - as a transformative approach to helicopter repair and replace for the US Army.
Peabody, Micah, Harrigan, William
Multi-Physics Informed Planning for Hybrid Metal Additive and Subtractive ManufacturingF-0081-2025-03555/20/2025
Hybrid additive manufacturing (AM) and subtractive manufacturing (SM) processes utilize the combination of AM (e.g., LPBF and DED) and SM (e.g., milling and turning operations) to produce the final part. Due to the poor surface roughness resulting from the uneven melting of powders in AM, the subtractive process is a necessary finishing operation to improve the surface roughness of the AM part. The hybrid AM/SM technology combines the benefits of AM and SM processes to create complex geometry while introducing good surface finish and compressive stress to prevent crack initiation. However, the relationship between large process parameter space and the residual stress/distortion in the part is not well understood, which impedes the adoption of hybrid AM/SM to minimize the residual stress in the final product. To expedite the process optimization, we establish a pipeline for the sequential modeling of additive manufacturing (AM) and subtractive manufacturing (SM) processes. Key
Lua, Jim, Li, Rui, Rajanna, Manoj, Haridas, Ravi Sankar, Mishra, Rajiv
Additive Manufacturing Design of a Vibration Isolator for Rotorcraft Simulator SeatsF-0081-2025-03795/20/2025
Helicopter pilots are exposed to a wide range of vibration frequencies, primarily generated by engine and rotor dynamics. These vibrations, particularly within the 0.5–80 Hz range, pose significant risks to pilot health, including musculoskeletal injuries and fatigue. To mitigate these effects, vibration isolators are employed, with passive and active isolation systems offering different advantages. This study investigates the initial design and performance of a novel metal additive manufactured vibration isolator, optimized for placement under the pilot's seat in a rotorcraft simulator. The isolator was designed with key structural parameters including stiffness, coil dimensions, and material properties while maintaining a lightweight and durable form, with a primary goal of validating the additive manufacturing of a metallic isolator. Experimental corroboration was conducted by incorporating modifications to the Gannon Biomechanics Flight Simulator test stand (GBFS), comparing the
Arzalluz, Irati, Ji, Xiaoxu, Piovesan, Davide, Marr, Conor
Mechanical Property Analysis of Triply Periodic Minimal Surface Structure with a Novel Hybrid Structure2025-01-82154/3/2025
Abstract Triply periodic minimal surface (TPMS) structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with
Tang, Haiyuan, Xu, Dexing, Sun, Xiaowang, Wang, Xianhui, Wang, Liangmo, Wang, Tao
EDITORIAL: Farewell and thanks, Mr. Birch21AUTP06_041/27/2025
“We pay close attention to the SAE magazines because your guy in Europe writes interesting articles,” a BMW engineering executive told me one year at the Frankfurt Motor Show. He was referring to Stuart Birch, our veteran European Editor, who has recently decided - after nearly 37 years of outstanding reporting for SAE International - to hang up his keyboard and spend more time with his wife, Kim, their family and friends in the British countryside, and his classic Porsche 911. Our staff had been dreading the day that Stuart would announce his retirement, foremost because he's been a great friend as well as a colleague. And because journalists with his qualities - professionalism, perspective, a powerful work ethic and great wit - are increasingly rare in the mobility-technology space. As SAE's global audience knew, Stuart Birch delivered compelling technical and business information. He covered product, processes and people with equal poise. And he thrived on the R&D beat: Virtual
Brooke, Lindsay
German OEMs flex 3D manufacturing muscle21AUTP03_081/27/2025
A chief impediment for wider adoption of additive manufacturing long has been its limited potential for application in high-volume and high-throughput production. But continuing process and technique developments from automakers and suppliers are moving additive manufacturing, also known as 3D printing, closer to high-volume Valhalla, while also enabling production of increasingly complex and substantial components. BMW has sporadically fitted specialized 3D-printed parts - both metal and polymer - in series-production models for more than a decade. Recently it has used its Rolls-Royce brand as a platform for introducing 3D-printing innovations in a low-volume but high-expectation environment. And in mid-2020, BMW invested some 15 million euros to establish its Additive Manufacturing Campus near Munich to research and develop new 3D printing processes and other innovations that might accelerate the potential for 3D-printed components at large scale. The company said the facility
Visnic, Bill
Scientists Fuse Simulations and Machine Learning to Accelerate Novel Additively Manufactured MaterialsTBMG-5212712/1/2024
Researchers at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, have demonstrated a novel approach for applying machine learning to predict microstructures produced by a widely used additive manufacturing technique. Their approach promises to dramatically reduce the time and cost of developing materials with tailored physical properties and will soon be implemented on a NASA-funded effort focused on creation of a digital twin.
These Speedy Cold Spray Machines Can 3D Print Vehicle Parts in War ZonesTBMG-5212212/1/2024
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/1/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Solvent-Free 3D Printing Material Could Enable Biodegradable ImplantsTBMG-5216712/1/2024
Duke University Durham, NC
Bio-Ink for 3D PrintingTBMG-5218912/1/2024
Biomedical engineers have developed a “bio-ink” for 3D-printed materials that could serve as scaffolds for growing human tissues to repair or replace damaged ones in the body. Bioengineered tissues show promise in regenerative, precision, and personalized medicine; product development; and basic research, especially with the advent of 3D printing of biomaterials that could serve as scaffolds or temporary structures to grow tissues.
Design and Development of Swashplateless Micro Helicopter with Pitch-Lag CouplingF-0080-2024-12915/7/2024
This paper presents the design and development of a swashplateless micro helicopter with a target endurance of more than 30 minutes using an optimized direct drive rotor connected to a unique rotor hub that has blades with a flap hinge and proprietary skewed-lag hinge with pitch-lag kinematic coupling. This obviates the need for conventional swashplate based cyclic pitch control, as the cyclic variation in control angle is achieved by cyclically varying the motor RPM. UP12 underactuated propulsion system developed by VertiQ is used for the baseline design. The blades in this propulsion system are optimized using Blade Element Momentum Theory (BEMT) analysis with lookup table to enhance its performance. BEMT is validated using experimental measurements and then used to optimize the geometry of the rotor. The optimized blades offer better performance and are 30% lighter than the original 3D-printed plastic blades. The prototyping of the Micro Aerial Vehicle (MAV) is completed by
Bhatnagar, Kirti, Abhishek, Abhishek, Arya, Bidhan, Bansal, Divyanshi
Manufacturing of Tools for Support Aviation Production using Fused Filament Fabrication and Fused Deposition Modeling Technologies, on the Example of PZL Mielec a Lockheed Martin CompanyF-0080-2024-13245/7/2024
In the proposed article, the authors will focus on two manufacturing method FUSED FILAMENT FABRICATION (FFF) and FUSED DEPOSITION MODELING (FDM) showing examples of application in aviation production and the resulting benefits.
Banaś, Aleksander, Burczy, Kamil, Wojtuszewski, Radosław, Głodzik, Marcin, Gałaczyński, Tomasz
Additive Manufacturing in the Mobility Industry: Vol. 2EPRCOMPV0220234/15/2024
Additive Manufacturing in the Mobility Industry: Vol. 2EPRCOMPV022023-TEST-REC4/15/2024
A General Workflow for Static Failure Criteria and Allowable Defect Size Calculation in Presence of Defects due to Manufacturing Process and Abusive Loads2024-26-03051/16/2024
Manufacturing processes such as casting, welding and additive manufacturing (AM) are prone to internal porosity and high surface roughness on the manufactured parts. These defects are inherent in the process and cannot be completely eliminated. Handling, transport and maintenance of manufactured parts can also lead to defects such as scratches and dents due to abusive loads. The defects can be characterized in a number of ways, assuming they resemble a U-notch or V-notch, elliptical pores, or a continuous distribution of consecutive defects in combination with surface roughness. The designer utilizes existing analytical and empirical equations to predict stress concentration due to presence of various types of defects and compute factor of safety to ensure structural integrity of design subjected to various load cases. The applicability of existing analytical and empirical equations is studied, and modifications are suggested to improve the predictions. The limits of analytical
Kishore, Prateek, Mishra, Suraj, Vemula, Sai, Puranik, Shashank, Jivani, Chinmay, Aher, Ravi
Reduction of carbon footprint using Additive Inspired design in Tractor Hydraulic systems2024-26-00701/16/2024
Tractor usage is growing due to introduction of wide range of implements and applications. Tractor plays a major role in Agri and Construction applications. Due to the environmental factors, restrictions are set on the tractor emissions. This brings new challenge in the tactor industry to reduce the carbon footprint. By reducing the weight of the tractor, Co2 emissions can be reduced. Many of the components in the Hydraulic systems are made of metal casting. Conventional casting process involves preparation of die & mold, material removal at unwanted regions, machining in the final stage to get the desired final product. Contrary to conventional manufacturing process, Additive Manufacturing process is a transformative approach to industrial production that enables creation of lighter and stronger parts. The process involves creation of 3D component by adding material layer by layer. The advantage of this method is the minimum wastage of raw material and possibility of integrated
Dumpa, Mahendra Reddy, Perumal, Solairaj, K, Bheshma, Gomes, Maxson, Magendran, G, Redkar, Dinesh, Londhe, Abhijit
Soft Robotic System for Brain SurgeryTBMG-497771/1/2024
Researchers have laid the groundwork for a soft robotic tool and control system that could grant surgeons an unprecedented degree of maneuverability within the brain. A recent study demonstrates that the new system is both intuitive and highly accurate. The early results suggest that, with further development, the robot could one day speed up and improve the efficacy of minimally invasive surgeries for life-threatening brain aneurysms and other serious conditions.
Process of Implementation and Certification of the First Parts Manufactured in Selective Laser Sintering Technology, on the Example of PZL Mielec a A Lockheed Martin CompanyF-0079-2023-181035/16/2023
Banas, Aleksander, Wojtuszewski, Radoslaw, Galaczynski, Tomasz, Glodzik, Marcin
Saw-Tooth Ramps for the Suppression of Flow-Acoustic Coupling in a High-Frequency Silencer for Turbocharger Compressors2025-01-00235/5/2023
The ported shroud casing treatment for turbocharger compressors is desirable for mitigating broadband/whoosh noise and enhancing boost pressures at low to mid flow rates. Yet, it is accompanied by elevated narrowband noise at the blade-pass frequency (BPF). Compressor BPF noise occurs at high frequencies where wave propagation is often multi-dimensional, rendering traditional planar wave silencers invalid. An earlier work introduced a novel reflective high-frequency silencer (baseline) targeting BPF noise in the 8-12 kHz range using an “acoustic straightener” that promoted planar wave propagation along arrays of quarter-wave resonators (QWRs). The design, however, faced challenges with high-amplitude tonal noise generation at specific flow conditions due to flow-acoustic coupling at the opening of the QWRs, thereby compromising the noise attenuation. The current study explores two QWR interface geometries that weaken the coupling, including linear and saw-tooth ramps on the upstream
Sriganesh, Pranav, Selamet, Ahmet
5 Ws of 3D-Printed MEMSTBMG-4693411/2/2022
3D Printing Materials with Tunable Mechanical PropertiesTBMG-4691211/1/2022
First 3D-Printed Nanostructured Alloy is Strong, DuctileTBMG-4691011/1/2022
Achieving Desired Level of Wettability for Unlikely MaterialsTBMG-4691111/1/2022
Inside the OEM: StrykerTBMG-4693811/1/2022
SAE TOMORROW TODAY: Additive Manufacturing on Earth and Beyond133149/23/2022
From industrial to medical to space, laser additive manufacturing and 3-D printing has the potential to transform production across nearly every sector. With almost one hundred years in business and nearly half a century in laser technology, TRUMPF has long been known as the gold-standard in advanced manufacturing solutions that now include additive manufacturing and 3-D printing. The company's advancements in production technology span space exploration, medical devices, and Smart Factory development. We sat down with Eliana Fu, Industry Manager for Aerospace & Medical at TRUMPF North America, to discuss how the company is transforming manufacturing processes for the better, both on earth and beyond. From assembling vehicles in space to manufacturing medical devices closer to the point of care to paving the way for the Smart Factory, TRUMPF is building the industrial world of tomorrow.
Hineman, Marcie
Thin, Stretchable Biosensors Could Make Surgery SaferTBMG-464939/1/2022
A research team developed bio-inks for biosensors that could help localize critical regions in tissues and organs during surgical operations. The ink is biocompatible and provides a user-friendly design with workable time frames of more than one day. Simultaneous recording and imaging could be useful during heart surgery in localizing critical regions and guiding surgical interventions such as a procedure for restoring normal heart rhythms.
Optimizing design for additive manufacturing22AUTP08_038/1/2022
Avoiding the pitfalls of 3D printing requires knowing the process limitations - and how to work around them. An expert at a leading AM specialist shares insights on getting it right. As additive manufacturing (AM) technology and its applications expand, engineers are recognizing that different industrial 3D printing processes have different constraints that can affect designed parts in production. Some constraints are universal across the different processes, and some are more specific to the type of process used. It is thus essential to understand the technology you are working with to maximize its potential as a production method. With this understanding it is possible to design around the general limitations of AM as well as the specific process constraints that could impact a product or part. While design for manufacture (DfM) is not a new concept, the rules for designing for additive manufacture (DfAM) require design engineers to take a different approach. This article is
Allen, Nick
3D Welding Additive Manufacturing Humanoid for Spacecraft2022-26-11935/26/2022
Space exploration is truly the most adventurous journey in the history of mankind. Satellites, space flights, and stations are deeper into the infinite expanse of the universe and these are susceptible to impact by orbital debris and meteoroids. In order to protect these machines from failures of their components and build new parts in space, we need an effective method to build 3D durable components in space. This paper discusses the usage of a LEMUR Robot for Additive Manufacturing using 3D Laser Welding. 3D laser welding uses a high concentration of energy to fuse the metal wires into a precise part that can withstand harsh conditions in the space environment. It offers high geometrical accuracy and material strengths. 3D welding uses laser metal fusion to build products layer by layer using the robotic arm attached to the Limbed Excursion Mechanical Utility Robot (LEMUR) which was originally designed to do repairs on the ISS. LEMUR has two legs and two arms which helps it to
Bhurat, Shryas, Yadav, Aashish, Shetty, Naman
The role of Additive Manufacturing in the era of Industry 4.0 2022-26-11695/26/2022
Progressive innovations enable businesses to stay ahead of competition while also increasing profits. These contributing dynamics have allowed the development of a number of advanced innovations, but no other paradigm has had a larger effect in recent decades than Industry 4.0. The unification of intelligent technological advances and manufacturing systems is promoted by Industry 4.0. Amongst which, additive Manufacturing(AM) plays a critical role in solving some of the 4th industrial revolution's key pressing concerns. Manufacturing was never more versatile, effective, or mechanized than in the Internet of Things(IOT) epoch. One can now develop ever-more complicated innovations which merge tangible items and data management. Automated machineries are capable of communicating with one another, exchanging and processing data, evaluating their operational situation in order to be self-adaptable and sometimes even making selections. All of which happens on its own with very little human
N, Harikeerthana, Kumar PhD, Sachin
Additive Manufacturing of Threaded Parts for Aerospace applications2022-26-11705/26/2022
Additive manufacturing also known as 3D printing and rapid prototyping is ‘the process of joining materials to make objects from 3D model data, generally layer upon layer. It is a suitable process to produce complex net shape parts, and prototypes. Additive Manufacturing empowers both design and industrial revolution, in various industrial sectors such as aerospace, energy, automotive, medical, tooling and consumer goods. In aerospace today, Additive Manufacturing is bringing lots of advantages and applications but manufacturing threaded fasteners or parts with threads is not much explored. In this study we are exploring this and trying to establish manufacturing threaded parts using additive manufacturing. This is going to give many benefits like reduced part cost, manufacturing and installation time and increased safety. The key features of such parts which makes AM as a best manufacturing method are – angled internal grove, provision for sealant for complete sealing, customized
Shetty, Dr. Kishora, Murthy, Harsha
V4-005 testSAE-PP-009634/26/2022
Heavy vehicles are essential for the modern economy, delivering critical food, supplies, and freight throughout the world. Connected heavy vehicles are also driven by embedded computers that utilize internal communication using common standards. However, some implementations of the standards leave an opening for a malicious actor to abuse the system. One such abuse case is a cyber-attack known as the “Address Claim Attack.” Proposed in 2018, this attack uses a single network message to disable all communication to and from a target electronic control unit, which may have a detrimental effect on operating the vehicle. This article demonstrates the viability of the attack and then describes the implementation of a solution to prevent this attack in real time without requiring any intervention from the manufacturer of the target devices. The defense technique uses a bit-banged Controller Area Network (CAN) filter to detect the attack. Once an attack is discovered, the defender induces a
Mutagaana, Festo
V4-003 Fk testSAE-PP-009614/26/2022
Heavy vehicles are essential for the modern economy, delivering critical food, supplies, and freight throughout the world. Connected heavy vehicles are also driven by embedded computers that utilize internal communication using common standards. However, some implementations of the standards leave an opening for a malicious actor to abuse the system. One such abuse case is a cyber-attack known as the “Address Claim Attack.” Proposed in 2018, this attack uses a single network message to disable all communication to and from a target electronic control unit, which may have a detrimental effect on operating the vehicle. This article demonstrates the viability of the attack and then describes the implementation of a solution to prevent this attack in real time without requiring any intervention from the manufacturer of the target devices. The defense technique uses a bit-banged Controller Area Network (CAN) filter to detect the attack. Once an attack is discovered, the defender induces a
Mutagaana, Festo
002-fkSAE-PP-009404/26/2022
Heavy vehicles are essential for the modern economy, delivering critical food, supplies, and freight throughout the world. Connected heavy vehicles are also driven by embedded computers that utilize internal communication using common standards. However, some implementations of the standards leave an opening for a malicious actor to abuse the system. One such abuse case is a cyber-attack known as the “Address Claim Attack.” Proposed in 2018, this attack uses a single network message to disable all communication to and from a target electronic control unit, which may have a detrimental effect on operating the vehicle. This article demonstrates the viability of the attack and then describes the implementation of a solution to prevent this attack in real time without requiring any intervention from the manufacturer of the target devices. The defense technique uses a bit-banged Controller Area Network (CAN) filter to detect the attack. Once an attack is discovered, the defender induces a
Mutagaana, Festo
0001-TestSAE-PP-009364/26/2022
Heavy vehicles are essential for the modern economy, delivering critical food, supplies, and freight throughout the world. Connected heavy vehicles are also driven by embedded computers that utilize internal communication using common standards. However, some implementations of the standards leave an opening for a malicious actor to abuse the system. One such abuse case is a cyber-attack known as the “Address Claim Attack.” Proposed in 2018, this attack uses a single network message to disable all communication to and from a target electronic control unit, which may have a detrimental effect on operating the vehicle. This article demonstrates the viability of the attack and then describes the implementation of a solution to prevent this attack in real time without requiring any intervention from the manufacturer of the target devices. The defense technique uses a bit-banged Controller Area Network (CAN) filter to detect the attack. Once an attack is discovered, the defender induces a
Mutagaana, Festo
Effects of Stress Concentrations due to Bead Geometry in Large Format Polymer Additive Manufacturing.2022-01-03983/29/2022
Advancements in polymer Additive Manufacturing (AM) have led to growing adoption for structural applications in the aerospace, defense, and automotive industries. Nevertheless, extrusion-deposition type polymer additive manufacturing produces bead-shaped surface artifacts which create local stress concentrations that reduce the load carrying ability of the manufactured part. It is important to understand and characterize the effects of these surface artifacts, particularly in large format applications, where the larger layer heights and highly filled materials can exacerbate the sensitivity to stress concentrations. In this work, tensile test coupons were cut from the side panels of additively manufactured boxes, and tested to failure under uniaxial loading in the Z-direction. The parts were printed with a conductive, nano-filled PEKK material to represent high-strength and high-temperature applications. The test coupons were divided into two sets, with one set having the bead
Kundurthi, Saratchandra
An Investigation of the simulation of sintering distortion in a 316L Part manufactured using Bound Metal Deposition 3D printing 2022-01-04143/29/2022
Metal binderjetting is a high throughput additive manufacturing process that has the potential to meet the needs of automotive volume production. In many cases, this process requires a sintering post-process to meet final dimensions. Because the sintering stage is performed free standing (i.e. without the use of tooling) and can involve up to a 20% dimensional change from green part to the final part shape, part distortion can be a concern. In this study, the sintering stage of a bridge geometry was simulated under different parameter settings using a Finite Element Analysis. The sensitivity of the simulation to various process parameter inputs was examined. Parts were then produced in 316L using a bound metal deposition and sintering process and compared to prediction. The sintering simulation indicated good agreement with experiment for some dimensions but highlighted the need for additional analysis.
Forsmark, Joy, Markland, Kyle, Godlewski, Taylor, Bai, Yun, Poczatek, Eric
Variable axial composite light weight automotive parts using anisotropic topology optimization and tailored fiber placement2022-01-04083/29/2022
Continuous fiber composites are an important material for realization of lightweight structures. In the last decade, there has been great progress in fabricating continuous fiber composite parts in terms of local fiber orientation control by robotics and the additive manufacturing technologies. These technologies include continuous fiber printing (CFP), tailored fiber placement (TFP) and automated fiber placement (AFP). One common challenge of these technologies resides in the design method. These methods can fabricate local orientation-controlled composites, so called variable axial composites (VACs), which show great performance improvement when appropriately designed for given loading conditions; however, they may not be as robust as conventional quasi-isotopic composites due to misalignment of load path and fiber path. Therefore, design of both structure and fiber orientation considering load conditions is highly critical and demands high engineering skills. To address this
Nomura, Tsuyoshi, Iwano, Yoshihiro, Kawamoto, Atsushi, Yoshikawa, Katsuharu, Spickenheuer, Axel
Microstructure Control with a Combined Metal Additive Manufacturing and Deformation Processing 2022-01-03233/29/2022
Direct metal additive manufacturing provides great flexibility in 3D shaping as compared with traditional manufacturing processes of metal casting, deformation followed by machining and joining for obtaining final production shape. On the other hand, it suffered from its dendric microstructure produced during solidification. This study reports the development of a new combined metal additive and deformation processes to take advantages and reduce/eliminate the drawback from individual process. There are many forms of direct metal deposition processes mainly categorized by the heating source and heat application method used. Similarly, there are also many deformation processes that can provide a wide range of applied stress, strain, strain rate and temperature, which ultimately determine the final microstructure and property of the product. One constraint for selection of deformation process is the need to provide local deformation to allow flexible 3D printing and forming. To
ELALEM, AHMED, Wu, Xin
Investigation of Al2O3-Ni coated cast iron brake rotors under modified brake dynamometer test standards2022-01-03093/29/2022
Due to the reduced or less-frequent usages of the friction brakes and the lower brake rotor temperature on electrical vehicles (EV), corrosion would much likely occur on brake rotors. Using hard braking to clean the corroded rotor surfaces often leads to extra rotor surface wear. Improvement in corrosion and wear resistance is an important technological topic to brake rotors for EVs. Many original equipment manufacturers (OEM) and their suppliers are exploring surface treatments including laser cladding and thermal spray processes on cast iron rotors to combat the corrosion issues. However, mentioned surface coating processes increase the cost of brake rotors and there is a need to search for cost-effective coating processes. In this research, a new Al2O3-Ni composite coating was proposed for preparation of a commercial cast iron brake rotor using both plasma electrolytic aluminating (PEA) and electroless nickel plating (ENP) processes. The added nickel was to fit in the intrinsic
Cai, Ran, Sun, Jiayi, Zhang, Jingzeng, Tjong, Jimi, Foots, Sean, Lavelle, Mark, Nie, Xueyuan
Anisotropic dynamic mechanical properties of 3D printed carbon fiber composites2022-01-03993/29/2022
3D printing is a revolutionary manufacturing method that allows the productions of engineering parts almost directly from modeling software on a computer. With 3D printing technology, future manufacturing could become vastly efficient. However, it has been reported that the 3D printed parts exhibit anisotropic behaviors in microstructure and mechanical properties, that is, depending on the positions (infill orientations) that the parts are placed on a printer platform, the properties of resultant parts can vary greatly. Further, parts made from 3D printing are found to exhibit properties inferior to those made using more conventional manufacturing methods, e.g., compression molding. So far, studies on anisotropic behaviors of 3D printed parts have been mostly limited to the static properties (modulus of elasticity, failure strength, etc.); there is a lack of understanding on the mechanical responses of 3D printed parts under dynamic conditions. In the present study, the anisotropic
Garcia, Jordan, Lu, Y Charles
Adjoint method in optimizing conformal cooling channels of 3-D printed high-pressure tools for aluminium casting2022-01-02813/29/2022
The emergence of additive manufacturing (AM) technology has enabled the internal cooling channel layout for high pressure aluminium die casting (HPADC) tools to be designed and modified without topological constraint. Optimisation studies of a full industrial HPADC mould for extending the tool service life has received limited attention due to the high geometrical complexity and the various physics with multi time and length scales in addition to the manufacturability limitations. In this work a new computational efficient algorithm that employs the adjoint optimization method has been developed to optimize the coolant channels layout in a complete mould with various 3D printed inserts. The algorithms reduced significantly the computational time and resources by decoupling the fluid flow in the coolant channels from the tool and simulating them separately. The channels heat transfer coefficient values are then interpolated and mapped into the thermal model that implements the adjoint
Zeng, Tongyan, Abo-Serie, Essam F., Jewkes, James, Dodd, Paul, Jones, Rhys
Non-isothermal Crystallization Kinetic Model: Theory, Development and Application2022-01-03223/29/2022
Semi-crystalline thermoplastic polymers have been poised by a renewed interest over the past decade. Though they have been continuously used in the automotive industry and other markets, high performance thermoplastics are now in the Aerospace industry target. The material's recyclable nature, low process cost and high impact resistance makes them very good candidates to succeed where thermosets have struggled. Despite many advancements in physics modeling of semi-crystalline thermoplastic manufacturing process, there are still parts of the physics that have been left out like process induced crystallinity and the inherent mechanical behavior. This work is a first step in the implementation of a process parameter-dependent crystallization kinetic model to evaluate the resultant crystallinity of thermoplastics. The proposed model is inspired by the crystallization kinetic work done by Yaghini & Peters which address fundamental aspects like primary and secondary crystallizations
Lavertu, Pierre-Yves
Stiffness optimization process using topology optimization techniques and lattice structures2022-32-00781/9/2022
In recent years, topology optimization technology has been widely applied as a means of achieving weight reduction. On the other hand, the development of additive manufacturing technology (3D printing) is making it possible to manufacture structures called lattices. In this paper, we show that it is possible to create even stiffer structures by combining both technologies, and we develop a design process that includes optimization calculations.
NAGAMOTO, Hiroyuki, KOBAYASHI, Koji, FUJITA, Hideyuki
Aluminum Alloy Powder 7.0Si - 0.55Mg - 0.12TiAMS7020 (Current)11/9/2021
This specification covers an aluminum alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Aluminum Alloy Powder 7.0Si - 0.55Mg - 0.12TiAMS7020-TEST-REC (Historical)11/9/2021
This specification covers an aluminum alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Laser Directed Energy Deposition Additive Manufacturing Process (L-DED)AMS7010A (Current)10/28/2021
This specification establishes process controls for the repeatable production of preforms/parts using the laser directed energy deposition (L-DED-) process for additive manufacturing. Preforms are intended to be used to manufacture aerospace parts, but usage is not limited to such applications. Feedstock may be either wire (for L-DED-Wire) or powder (for L-DED-Powder).
AMS AM Additive Manufacturing Metals
Sensor-controlled Friction Materials based on Liquid Friction Compounds, Chip-in-Pad Concept2021-01-129610/11/2021
In this paper, the concept of integrating thin-film piezo transducers into friction pads by using a liquid friction material compound (LIQFRIC® HP), which is capable of completely embedding the sensor surface and allowing for the force transfer due to a direct contact between sensor and friction material, is explained. The low thickness of the sensor allows for an excellent ratio of sensor volume / friction volume in the pad. The piezo transducer, besides being able to detect positive and negative pressure changes, can also be used via its EMI capability to allow measurements of changes in the shape (and therefore thickness) of the pad during and after testing. Measuring the pressure distribution, the wear and possible defect situations of the pad potentially opens up new means of friction pad- and brake operations or developments.
Milczarek, Roman Paul
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