Development and airworthiness certification of state of art additively manufactured AlSi10Mg mission critical selector valve body part for aerospace

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Abstract

Aerospace applications can benefit from additive manufacturing (AM), which is highly advantageous for prototyping and rapid manufacturing. It also offers cost and weight savings, as well as integrated design capabilities. As of now, there are only a few AM standards available, many materials and equipment are involved, resulting in many variables that hinder certification and adoption. As a result, nonstandard testing is making AM in the airborne materials less appealing due to its costly and time-consuming nature. The main objective of this work is to manufacture the Selector Valve Body parts of military and civil aircraft through Laser Powder Bed Fusion (LPBF) process using AlSi10Mg powder. Further, this paper has been carried out the metallurgical properties, non-destructive and destructive testing as well as the clear explanation about the certification procedures. Moreover, this underscores the need for the developing guidelines, and standards that cover all aspects of manufacturing from design to manufacturing to operation. A comprehensive analysis from liquid penetration test shows defects are within the permissible level. In addition, it exhibits higher yield strength, ultimate strength, and elongation of (259±4) MPa, (323±4) MPa, and (12.5±1.5) % respectively, along with factual evidence that the precipitation hardened AlSi10Mg indigenously developed and produced is equal in properties to the equivalent precipitation hardening aluminium alloys produced by internationally renowned manufacturers. 

About the authors

Ponnusamy Vignesh

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Author for correspondence.
Email: vigneshpt3532@gmail.com
ORCID iD: 0000-0003-4487-2030

PhD, Junior Specialist-1

India

K.V. Praveen

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Email: praveenkv61@gmail.com

Bachelor of Engineering, Technical Assistant

India

Subbulakshmi Krishnakumar

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Email: krishna.ks0531@gmail.com

Bachelor of Engineering, Technical Assistant

India

Mohanrao Chembu Bhuvaneswari

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Email: cm.cemilac@gov.in

Bachelor of Engineering, Regional Director (Sc ‘F’)

India

Shirish Sharad Kale

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Email: shirish.kale.cemilac@gov.in

Ph.D., Director (Sc ‘G’)

India

Theagarajan Ram Prabhu

RCMA (F&F), CEMILAC, Defence R&D Organization, Bangalore

Email: ramprabhu.t@gmail.com

Ph.D., Joint Director (Sc ‘E’)

India

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