Optimization of Additive Manufacturing of Aluminium Alloy 356 for Aerospace Applications

增材制造（AM）是指一种新兴的技术，它通过以一层一层的方式控制材料的添加，以生产达到或接近最终形状的物体，从而构建3D物体。复合材料与铝合金（AA）的结合成为轻量化部件的关键。然而，已证实的AA和AM的组合仅限于两种合金，即AlSi12和AlSi10Mg。缺乏A356非结构件增材制造知识，后续热处理进度和几何限制是建立这个项目的主要原因。该方案由加拿大铝业协会（AAC）、加拿大普惠公司（PWC）、加拿大贝尔直升机德事隆（BHTC）、雷尼绍、FusiA和麦吉尔大学共同设计，将解决现有的知识空白，允许采用选择性激光熔化加工制造当前和未来的A356航空航天部件。要探索的现象包括增材制造工艺参数与凝固组织之间的关系，以及在时效硬化和Si相奥斯特瓦尔德细化过程中发生的竞争相互作用的平衡，这些相互作用将决定力学性能和变形行为。这些关系将以制造通用铝基航空航天部件的几何准则的形式实现。所有工业伙伴都带着具体的技术目标进入该项目，并将在拟议的研究中发挥关键作用。AAC的任务是从概念验证组件开始提高增材制造在人工智能转型领域的采用率。普华永道将通过制造传统铸造方法无法加工的非结构件来提高竞争力。BHTC看到了降低成本的关键机会，为他们的旧车提供过时的铝铸件替换零件。雷尼绍将增强其作为航空航天工业OEM AM制造商的技术领先地位。FusiA将提高其对356 AM的相关知识。这项研究的传播将提高加拿大在航空航天领域增材制造技术采用率方面的地位。

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.