Three-Dimensional Thermomechanical Finite Element Analysis of Additive Manufactured Aircraft Bracket through Laser Powder Bed Fusion

Abstract

This study presents the development of an aircraft bracket through the laser powder bed fusion (LPBF) additive manufacturing process. The investigation incorporates distinct critical process parameters, namely build orientation (X, Y and Z) and material properties such as stainless steel 316L, AlSi10Mg and Ti-6Al-4V. The primary focus is on assessing residual stresses and deformation, with the objective of determining the optimal process parameter combinations. Numerical simulations are conducted using Altair Inspire AM software. Certain demerits of deformation and residual stress-related cracking are identified as irreparable through post-processing interventions. An understanding of the interdependencies among input process parameters yields insightful observations. Specifically, the study reveals a positive correlation between build orientation in Y-Direction and an increase in residual stresses. However, dimensional deformation remains relatively unaffected by any build orientation. Optimal results are observed when utilizing aluminium as the material, with X-Direction as the preferred build orientation. However, it's important to note that different materials should also be assessed according to their material properties and printing needs. These findings underscore the critical importance of parameter selection and process optimization within LPBF to address inherent challenges.