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Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys / Ben Haigh

Swansea University Author: Ben Haigh

  • E-Thesis – open access under embargo until: 13th March 2029

DOI (Published version): 10.23889/SUthesis.65831

Abstract

With the continuous evolution of the aerospace industry, there is a strong desire to fabricate more intricate components in the modern jet engine that exhibit less stress-raising features to enable higher engine efficiencies to be achieved. To achieve this goal, aerospace engineers are looking at ad...

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Published: Swansea, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: Ph.D
Supervisor: Lancaster, Robert J.
URI: https://cronfa.swan.ac.uk/Record/cronfa65831
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first_indexed 2024-03-13T10:31:03Z
last_indexed 2024-03-13T10:31:03Z
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spelling v2 65831 2024-03-13 Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys 041f978ff61d78231663415fa21c9cdf Ben Haigh Ben Haigh true false 2024-03-13 FGSEN With the continuous evolution of the aerospace industry, there is a strong desire to fabricate more intricate components in the modern jet engine that exhibit less stress-raising features to enable higher engine efficiencies to be achieved. To achieve this goal, aerospace engineers are looking at additive manufacturing (AM) as a potential solution since AM provides a manufacturing technique that uses less raw material in the form of a powder, saving material which in turn reduces the cost of the process. One of the major limitations of AM is the resulting transient nature of the microstructure typically produced by the process, and it is difficult to fabricate representative laboratory scale mechanical test specimens that closely replicate the microstructure of the finished component. Therefore, it can be beneficial to utilise more novel small-scale test methods, such as the small punch (SP) test and shear punch (ShP) test, which can obtain mechanical property information from miniaturised specimens extracted directly from the finished part. In this research programme, correlations have been made between standard conventional testing techniques and the novel small-scale methods to investigate the suitability of using such methods in characterising the mechanical properties of laser powder bed fused (LPBF) aerospace materials, namely the nickel based polycrystalline superalloy, Inconel 718, and the titanium alloy, Ti-6Al-4V specimens. Furthermore, effort will be directed towards identifying whether small scale test methods can effectively establish whether the mechanical response of additively manufactured components vary within a single build, or likewise, across different builds, which could provide a key insight for design engineers both now and in the future. E-Thesis Swansea, Wales, UK Additive Manufacturing, Small Punch Testing 9 1 2024 2024-01-09 10.23889/SUthesis.65831 COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University Lancaster, Robert J. Doctoral Ph.D EPSRC doctoral training grant EPSRC doctoral training grant 2024-03-13T10:39:13.2360424 2024-03-13T10:27:31.4246838 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Ben Haigh 1 Under embargo Under embargo 2024-03-13T10:37:00.0336517 Output 8818095 application/pdf E-Thesis – open access true 2029-03-13T00:00:00.0000000 Copyright: The author, Benjamin Haigh, 2024. true eng
title Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
spellingShingle Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
Ben Haigh
title_short Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
title_full Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
title_fullStr Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
title_full_unstemmed Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
title_sort Novel Test Techniques to Characterise the Mechanical Performance of Additive Manufactured (AM) Aerospace Alloys
author_id_str_mv 041f978ff61d78231663415fa21c9cdf
author_id_fullname_str_mv 041f978ff61d78231663415fa21c9cdf_***_Ben Haigh
author Ben Haigh
author2 Ben Haigh
format E-Thesis
publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUthesis.65831
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 0
active_str 0
description With the continuous evolution of the aerospace industry, there is a strong desire to fabricate more intricate components in the modern jet engine that exhibit less stress-raising features to enable higher engine efficiencies to be achieved. To achieve this goal, aerospace engineers are looking at additive manufacturing (AM) as a potential solution since AM provides a manufacturing technique that uses less raw material in the form of a powder, saving material which in turn reduces the cost of the process. One of the major limitations of AM is the resulting transient nature of the microstructure typically produced by the process, and it is difficult to fabricate representative laboratory scale mechanical test specimens that closely replicate the microstructure of the finished component. Therefore, it can be beneficial to utilise more novel small-scale test methods, such as the small punch (SP) test and shear punch (ShP) test, which can obtain mechanical property information from miniaturised specimens extracted directly from the finished part. In this research programme, correlations have been made between standard conventional testing techniques and the novel small-scale methods to investigate the suitability of using such methods in characterising the mechanical properties of laser powder bed fused (LPBF) aerospace materials, namely the nickel based polycrystalline superalloy, Inconel 718, and the titanium alloy, Ti-6Al-4V specimens. Furthermore, effort will be directed towards identifying whether small scale test methods can effectively establish whether the mechanical response of additively manufactured components vary within a single build, or likewise, across different builds, which could provide a key insight for design engineers both now and in the future.
published_date 2024-01-09T10:39:11Z
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score 11.037603

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