Optimization of Additive Manufacturing of Aluminium Alloy 356 for Aerospace Applications

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Additive Manufacturing (AM) refers to an emerging class of technologies that build 3D objects by the controlled addition of materials in a layer-by-layer fashion to produce objects at or near their final shape. Combining AM and aluminum alloys (AA) becomes key in light weighting components. However, the proven combination of AA and AM is limited to two alloys, namely AlSi12 and AlSi10Mg. The lack of knowledge in AM of A356 for non-structural components, subsequent heat treatment schedule and geometry limits are the primary reasons for the establishment of this project. This proposal, co-designed by Association of Aluminum Canada (AAC), Pratt Whitney Canada (PWC), Bell Helicopter Textron Canada (BHTC), Renishaw, FusiA and McGill University, will address the existing knowledge gaps, permitting the adoption of selective laser melting processing for the fabrication of current and future A356 aerospace components. The phenomena to be explored include the relationship between AM processing parameters and the solidification microstructure, and the balance of the competitive interactions to be occurring during age hardening and Ostwald repining of the Si phase, interaction that will dictate the mechanical properties and deformation behavior. These relationships will be implemented in the form of geometrical guidelines for the fabrication of generic Al-based aerospace components. All industrial partners are entering the project with specific technological objectives and will play a key role in the proposed research. AAC has as mandate to increase the adoption rate of AM in the Al transformation sector from proof of concept components. PWC will improve their competitiveness by fabricating non-structural Al parts that cannot be processed by traditional casting methodologies. BHTC sees the key opportunity to reduce the cost for the providing of obsolete Al casting replacement parts for their older vehicles. Renishaw will augment its technological leadership as OEM AM manufacturer in the aerospace industry. FusiA will improve its knowledge related to AM of 356. The dissemination of the research will improve Canada's position in adoption rate of AM technologies in the aerospace sector.