About this Abstract |
Meeting |
2022 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2022)
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Symposium
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2022 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2022)
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Presentation Title |
Wire-arc Fabrication of Topology Optimized Aviation Components |
Author(s) |
Nic Tomanelli, Ben Nguyen, Daniel Chrivasuta, Matthew Martin, Nathanael High, Christopher B Williams, Sam Pratt |
On-Site Speaker (Planned) |
Sam Pratt |
Abstract Scope |
Hybrid wire arc am (hWAAM) processing provides an opportunity for onsite maintenance and repair of damaged aviation components that would otherwise be costly to reproduce and/or deliver. The aim of this project is to explore the suitability of hWAAM for this application via a case study aimed to redesign an aerospace component for processing via hWAAM in Al5556. A screening study verified design and material constraints. These findings and the part loading conditions were used to topologically optimize (TO) the component, resulting in reduced mass, cost, and production time compared to the original casting. The output of the TO solver was then used as the basis for the final design, incorporating DfAM rules required for our specific process. The part was then printed, machined where necessary, and load tested to validate its performance compared to the OEM component, resulting in 20% lower mass and substantial cost and time savings. |
Proceedings Inclusion? |
Definite: Post-meeting proceedings |