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In and Ex-Situ Process Development in Laser-Based Additive Manufacturing

Juhasz, Michael J.
http://rave.ohiolink.edu/etdc/view?acc_num=ysu15870552278358

Abstract Details

2020, Doctor of Philosophy in Materials Science and Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
Aircraft are currently flying much longer than their original design cycle with maintenance and logistics being paramount for keeping these aircraft flying. These aircraft require critical parts that may be out of production for a variety of reasons. This report is a subset of a larger project which looks to assess the role of additive manufacturing in assisting the aircraft supply chain with the production of spares and maintenance componentry. Addressed within the report is process development in both hybrid directed energy deposition additive manufacturing and laser powder bed fusion post-processing. Hybrid additive manufacturing combines additive manufacturing and traditional subtractive processing with synergistic layer-wise access. One benefit of an integrated, in-envelope suite of manufacturing processes is access to the structure at intermediate layers during fabrication. Implantation of sensors can inform the process of predictive maintenance and structural health management. These sensors can even support the qualification of the smart metal structures based on in-situ validation/qualification of the manufacturing process. Process development in this area will enable the next generation of aerospace components capable of providing sensing data from within the structure. This development resulted in the successful creation of proof-of-concept components which implemented both active and passive sensors. Laser powder bed fusion produced AlSi10Mg parts are being explored as a potential method for replacement of castings in aerospace applications. Maximizing the mechanical properties of this alloy is desirable to meet or exceed the performance of castings made of alloys such as A356. Like their traditionally produced counterparts, additively manufactured parts raise concerns about post-process induced distortion. Transverse isotropy and “as-produced” cellular microstructures also add to these concerns and are unique to LPBF parts. Here the results will be presented from a design of experiments examining the post processing conditions of hot isostatic pressing, quench rate, and the length and temperature of artificial aging against existing heat treatment schedules. For the first time, the post-processing heat treatment of AlSi10Mg to include hot isostatic pressing followed by precipitation hardening heat treatments has been significantly characterized with hot isostatic pressing being shown to accelerate artificial aging.
Brett Conner, Ph.D. (Advisor)
Pedro Cortes, Ph.D. (Committee Member)
Eric MacDonald, Ph.D. (Committee Member)
Virgil Solomon, Ph.D. (Committee Member)
Jason Walker, Ph.D. (Committee Member)
189 p.
Aerospace Materials; Engineering; Materials Science; Metallurgy
Additive Manufacturing; Hybrid Manufacturing; Directed Energy Deposition; Laser Powder Bed Fusion; AlSi10Mg

Recommended Citations

Citations

  • Juhasz, M. J. (2020). In and Ex-Situ Process Development in Laser-Based Additive Manufacturing [Doctoral dissertation, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu15870552278358

    APA Style (7th edition)

  • Juhasz, Michael. In and Ex-Situ Process Development in Laser-Based Additive Manufacturing. 2020. Youngstown State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu15870552278358.

    MLA Style (8th edition)

  • Juhasz, Michael. "In and Ex-Situ Process Development in Laser-Based Additive Manufacturing." Doctoral dissertation, Youngstown State University, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=ysu15870552278358

    Chicago Manual of Style (17th edition)

ysu15870552278358
971
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This open access ETD is published by Youngstown State University and OhioLINK.