Additive Manufacturing of Ti-6Al-4V Aero Engine Parts: Qualification for Reliability

The present paper highlights the study carried out on the qualification aspects of aero engine parts manufactured through additive manufacturing process. The study covers mainly the parts of aeronautical workhorse material Ti-6Al-4V in terms of quality and reliability aspects contributing toward airworthiness. The mechanical properties of various methods of additive manufacturing have been compared, and manufacturing process parameters have been studied. The paper also highlights the process validation parameters and qualification approach for this type of manufacturing. Possible failure modes and imperfections have been focused with respect to their effect on quality and reliability of the end product. The failure mitigation plan has been evolved through a three-tier approach which will be very useful to ensure the reliability of the aero engine parts. © 2018, ASM International.