Mechanical characterization of additively manufactured Ti-6Al-4V aircraft structural components produced by electron beam melting

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2022-8-25

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Yılmaz, Fatih

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Weight reduction of structural parts is one of the most important efforts of design and analysis studies to improve fuel efficiency and flight performance of aerospace vehicles through topology optimization creating complex geometric designs that are lighter but cannot be produced via conventional manufacturing methods. Instead, the manufacturing of the resulting designs is possible with additive manufacturing methods where the final product is obtained by adding layer upon layer to obtain close to the near-net-shape. However, the material properties produced by additive manufacturing are not standardized and fully known. Therefore, this thesis aims to obtain the tensile, fatigue, and pin-bearing material properties of Ti-6Al-4V alloy produced by electron beam melting (EBM) with test campaigns carried out according to ASTM standards. Test specimens are manufactured in three build directions, and the effect of build direction on material properties is investigated. Additionally, the effect of hot isostatic pressing (HIP) as a post-treatment revealed that the unwanted pores in the material are almost thoroughly closed. Having obtained the material properties, the pylon fitting of an unmanned aerial vehicle is lightened by topology optimization. Finally, as novel scientific contributions, this study includes comprehensive test campaigns and investigates the effects of three orthogonal build directions on elastoplastic properties, while many studies focus on only two-build directions. Evaluation of Poisson’s ratio is the other originality of this study. Furthermore, another finding through micro CT imaging is that temporary support structures result in intense defects closer to applied surfaces; hence high-stress regions of structures should be avoided to use support structures.

Subject Keywords

Additive Manufacturing, Electron Beam Melting, Titanium, Topology Optimization, Unmanned Aerial Vehicle Structural Component

URI

https://hdl.handle.net/11511/99449

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Graduate School of Natural and Applied Sciences, Thesis

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Citation Formats

F. Yılmaz, “Mechanical characterization of additively manufactured Ti-6Al-4V aircraft structural components produced by electron beam melting,” Ph.D. - Doctoral Program, Middle East Technical University, 2022.