Assessment of “As-Printed”, Machined & Post Processed Additive Layer Manufactured (ALM) Ti-6Al-4V for Aerospace Applications

Author:  S. L. Jenkins, D. P. Davies, J. P. Fuhr, S. McArthur
Source:  ICSP-13
Doc ID:  2017038
Year of Publication:  2017
Abstract:  
Introduction: Especially within the aerospace field there is a large interest in manufacturing increasingly complex components in the most economical way based on the relatively small volumes required by this industry. A very promising technology that may fulfil these requirements is the Additive Layer Manufacturing (ALM) process which is already used for an increasing number of metallic and nonmetallic components usually under static loads only. Within this paper the focus is on the fatigue performance and cyclic loading of ALM components made of Ti-6Al-4V material widely used in the aerospace industry. Fatigue samples were treated by different processes including machining, shot peening and superfinishing after the “printing process”. In addition, the post ALM treatments have been applied in variations and combinations to determine their individual effect on the fatigue strength of the ALM components. Based on the initial characterisation trials carried out by the Leonardo Materials Laboratory, on the static and fatigue property data for ALM produced Ti-6Al-4V, [1] Design Engineers have used this data to model and stress two ALM parts. As one of these parts was a flight critical part, Design and Stress Engineers required additional fatigue test data on both “As Printed” ALM and the effect post processing techniques, e.g. shot peening and/or superfinishing had on the fatigue properties of “As Printed” ALM. Consequently, this paper summarises the main topics results of the evaluation carried out by the Leonardo Materials Laboratory on “As Printed”, machined and post processed ALM produced Ti-6Al-4V especially in terms of fatigue performance.