Innovative Re-Design and Validation of Complex Airframe Structural Components Formed by Additive Manufacturing for Weight and Cost Reduction

Deliverables

Documents, reports (6)

Fatigue characterization of at least two of the post processes evaluated in D2.3

The S-N curves and fatigue limit for specimens with an as built AM surface will be compared to that of specimens with different post processing histories. The results will be analyzed and reported.

Evaluation of at least five different post processes for improved surface characteristics

Several different post processing methods will be investigated and their effect on fatigue performance of EBM and SLM surfaces will be determined.

Demands for complex metal AM design and modelling

A report that links critical metal powder bed AM process parameters and post-processing options to the designer’s geometrical specifications. The report will suggest how these interrelated parameters could be controlled in a CAE-assisted design environment to improve the designer’s ability to predict the performance of components built by powder bed AM.

Material characterization of surface and anisotropic properties

The mechanical properties of AM components will be dependent of the building orientation. There are several different reasons for this but the main source of anisotropy comes from; (1) non-random grain orientation due columnar grain growth during the building process, (2) the impact of the high surface roughness for thin structures elongated in one direction, (3) non-random orientation or clustering of defects along a certain direction caused by either lack of fusion or hot cracking between columnar grains during solidification and cooling. Mechanical testing will be will be performed on samples with different geometries, processing histories and orientations. The results will be analyzed and reported.

Final dissemination and exploitation plan

The final update and publication of the dissemination and exploitation plan

Initial dissemination and exploitation plan including communication

One of the key objectives of the project is to maximise the impact of the project results by dissemination and exploitation activities including communication. Further, dissemination and exploitation of project results are an obligation for every Horizon 2020 project. Therefore, the project will set up a dissemination and exploitation plan at the beginning of the project which will be then carried on and updated throughout the project's lifespan.

Other (3)

Communication between Catia and FEA/TO software

A computer implementation which makes it possible for a geometry description in CATIA to be used by a mesh generator, giving input to the FE program TRINITAS.

Computer implementation of TO method for optimal AM including uncertainty

A computer implementation of the deterministic approach to uncertainties that considers residual stresses and uncertain material properties.

Computer implementation of TO method for optimal AM

A computer implementation of TO, based on the SIMP approach, taking into account (1) anisotropic material properties, (2) the built direction of the AM process, (3) graded material, and (4) stress constraints modeling experimentally determined yield and strength properties.

Websites, patent fillings, videos etc. (1)

Web-site and other dissemination material

The purpose of this deliverable is to to develop the project website and to create the dissemination materials to promote and communicate the project at local, national and European level.

Publications

Peer reviewed articles (8)

Topology optimization accounting for surface layer effects

Author(s): Shyam Suresh, Carl-Johan Thore, Bo Torstenfelt, Anders Klarbring
Published in: Structural and Multidisciplinary Optimization, 2020, ISSN 1615-147X
DOI: 10.1007/s00158-020-02644-x

Continuous-time, high-cycle fatigue model: Validity range and computational acceleration for cyclic stress

Author(s): Stefan B. Lindström, Carl-Johan Thore, Shyam Suresh, Anders Klarbring
Published in: International Journal of Fatigue, Issue 136, 2020, Page(s) 105582, ISSN 0142-1123
DOI: 10.1016/j.ijfatigue.2020.105582

Design for additive manufacturing – a review of available design methods and software

Author(s): Anton Wiberg, Johan Persson, Johan Ölvander
Published in: Rapid Prototyping Journal, Issue ahead-of-print/ahead-of-print, 2019, ISSN 1355-2546
DOI: 10.1108/rpj-10-2018-0262

Improved fatigue strength of additively manufactured Ti6Al4V by surface post processing

Author(s): M. Kahlin, H. Ansell, D. Basu, A. Kerwin, L. Newton, B. Smith, J.J. Moverare
Published in: International Journal of Fatigue, Issue 134, 2020, Page(s) 105497, ISSN 0142-1123
DOI: 10.1016/j.ijfatigue.2020.105497

Topology optimization using a continuous-time high-cycle fatigue model

Author(s): Shyam Suresh, Stefan B. Lindström, Carl-Johan Thore, Bo Torstenfelt, Anders Klarbring
Published in: Structural and Multidisciplinary Optimization, Issue 61/3, 2020, Page(s) 1011-1025, ISSN 1615-147X
DOI: 10.1007/s00158-019-02400-w

Penalty regulation of overhang in topology optimization for additive manufacturing

Author(s): C.-J. Thore, H. Alm Grundström, B. Torstenfelt, A. Klarbring
Published in: Structural and Multidisciplinary Optimization, Issue 60/1, 2019, Page(s) 59-67, ISSN 1615-147X
DOI: 10.1007/s00158-019-02194-x

Improved fatigue strength of additively manufactured Ti6Al4V by surfacepost processing

Author(s): M. Kahlin, H. Ansell, D. Basu, A. Kerwin, L. Newton, B. Smith and J.J. Moverare
Published in: International Journal of Fatigue, Issue Volume 134, May 2020, 105497, 2020, ISSN 1879-3452

Variable amplitude loading of additively manufactured Ti6Al4V subjected to surface post processes

Author(s): M. Kahlin, H. Ansell, A. Kerwin, B. Smith, J. Moverare
Published in: International Journal of Fatigue, Issue 142, 2021, Page(s) 105945, ISSN 0142-1123
DOI: 10.1016/j.ijfatigue.2020.105945

Other (9)

Developments in Topology Optimization in the ADDMAN Project

Author(s): Henrik Alm Grundström
Published in: Report, Issue ISRN: LIU-IEI-WP--18/00009—SE, 2018

Additive Manufacturing in Aerospace – Fatigue Life Improvement and Novel Design Tools

Author(s): N. Cruchley
Published in: Clean Sky 2 event, 2019

Trinitas Topology Optimization Tutorial Document

Author(s): Henrik Alm Grundström
Published in: Tutorial Document, 2018

Adaptive Abrasive Finishing of AM Components through In-Process Monitoringand Tool-Path Corrections (oral presentation)

Author(s): D. Gilbert, D. Basu, B. Smith
Published in: 2018 ASPE and euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing, 2018, Page(s) 292

TOPOLOGY OPTIMIZATION USING AN EVOLUTION-BASED ANISOTROPIC HIGH-CYCLE FATIGUE CONSTRAINT

Author(s): S. Suresh, S.B. Lindström, C.-J. Thore, B. Torstenfelt, A. Klarbring
Published in: Issue Swedish Mechanics Days (SMD) 2019, 2019

Topology optimization using an evolution-base anisotropic high-cycle fatigue constraint

Author(s): S. Suresh, S.B. Lindström, C-J. Thore, B. Torstenfelt and A. Klarbring
Published in: 2019

A topology optimisation method for as-build metal additive manufacturing (oral presentation)

Author(s): S. Suresh, C-J. Thore, A. Klarbring
Published in: 2019

Improved fatigue properties of additive manufactured Ti6Al4V for aerospace by various surface post processes (oral presentation)

Author(s): M. Kahlin, H. Ansell and J. Moverare
Published in: 2019

The AddMan Project: Innovative Re-Design and Validation of Complex Airframe Structural Components Formed by Additive Manufacturing for Weight and Cost Reduction (poster)

Author(s): S. Stekovic, J. Moverare, A. Klarbring, S. Lindström, C-J. Thore, J. Ölvander, A. Wiberg, B. Smith, A. Triantaphyllou, A. Kiely, A. Kerwin, S. Samanthula, M. Kahlin, N. Eriksson
Published in: Aerospace Technology Congress 2019, 2019

Thesis dissertations (3)

Topology Optimization for Additive Manufacturing Considering Stress and Anisotropy

Author(s): Henrik Alm Grundström
Published in: Independent thesis advanced level, Issue ISRN: LIU-IEI-TEK-A--17/02790—SE, 2017

Topology Optimization as Tool for Development of an Additive Manufactured Aircraft Component

Author(s): N. Axelsson and M. Brantemo
Published in: 2019

Towards Design Automation for Additive Manufacturing: A Multidisciplinary Optimization approach

Author(s): Anton Wiberg
Published in: Swedish Licentiate Thesis, 2019

Conference proceedings (4)

AN OPTIMIZATION FRAMEWORK FOR ADDITIVE MANUFACTURING GIVEN TOPOLOGY OPTIMIZATION RESULTS

Author(s): Anton Wiberg, Johan Persson and Johan Ölvander
Published in: Proceedings of the Tools and Methods of Competitive Engineering (TMCE) 2018 Symposia edited by I. Horváth and J.P. Suárez, Issue 7-11 May, 2018, Las Palmas de Gran Canaria, Spain, 2018, Page(s) 533-542

An Evolution-Based High-Cycle Fatigue Constraint in Topology Optimization

Author(s): Shyam Suresh, Stefan B. Lindström, Carl-Johan Thore, Bo Torstenfelt, Anders Klarbring
Published in: EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization, 2019, Page(s) 844-854
DOI: 10.1007/978-3-319-97773-7_73

Design for Additive Manufacturing Using a Master Model Approach

Author(s): Anton Wiberg, Johan Persson, Johan Ölvander
Published in: Volume 2A: 45th Design Automation Conference, 2019
DOI: 10.1115/detc2019-97915

Using Boundary Condition and Topology Optimization to Design an Airplane Component

Author(s): Johan A. Persson, Anton Wiberg
Published in: AIAA Scitech 2020 Forum, 2020
DOI: 10.2514/6.2020-0547