Research Progress in the Additive Manufacturing of AluminiumAlloys for Aerospace Applications
Author of the article:ZHOU Quan1, QIU Shengsheng2, JIANG Wenhuang2, HE Xiandi2, ZHANG Siyuan1, ZHANG Bowei1
Author's Workplace:1. Beijing Institute of Space Mechanics & Electricity, Beijing 100094, China; 2. Luzhou Hanfei Aerospace TechnologyDevelopment Co., Ltd., Luzhou 646000, China
Key Words:aerospace aluminium alloys; additive manufacturing; laser powder bed fusion; wire arc additivemanufacturing; directed energy deposition; engineering applications
Abstract:
With the development of aerospace equipment for lightweight, integrated, and highly reliable structures,conventional manufacturing processes for aluminium alloys are becoming increasingly unable to meet the requirements ofadvanced aircraft and spacecraft in terms of complex-structure fabrication, material utilization, and manufacturing cycles.Owing to its high design freedom, near-net-shaped forming capability, and advantages in integrated structuralmanufacturing, additive manufacturing provides a new technical route for the fabrication of aerospace aluminium alloycomponents. Focusing on recent progress in additive manufacturing of aluminium alloys for aerospace applications, thispaper systematically reviews the characteristics of major additive manufacturing processes, including laser powder bedfusion, wire arc additive manufacturing, and directed energy deposition. The forming behavior, microstructural evolution,defect control, and property regulation of typical aluminium alloy systems, including Al-Si, Al-Cu, Al-Mg, Al-Mg-Si, andAl-Zn-Mg-Cu alloys, are analysed in detail. In addition, representative engineering applications, such as lightweightbrackets, communication satellite waveguides, space optical components, and rocket propellant tanks, are summarized toillustrate the current application status of additively manufactured aluminium alloys in aerospace components. Finally, keychallenges in aerospace aluminium alloy additive manufacturing, including hot cracking, porosity, residual stress,microstructural anisotropy, and service reliability, are discussed, and future development directions are proposed, includingthe design of aluminium alloys specifically for additive manufacturing, intelligent process control, synergistic optimizationof postprocessing, and standardization and certification.