The Application of Direct Metal Laser Sintering (DMLS) of Titanium Alloy Powder in Fabricating Components of Aircraft Structures

Abstract

This study presents detailed characteristics of the DMLS method as used for titanium alloy powder with reference to a possible intended use in aeronautics applications.In the present study test models were made, designed for trials in which the model material properties are to be determined and which specify the basic features of the RP/DMLS technique. In order to evaluate the ultimate use of the DMLS technique in fabricating titanium alloy parts, the following procedures were conducted: tensile and upsetting tests for Ti6Al4V alloy samples (a comparative analysis for DMLS models and models fabricated, respectively, from titanium sheet and bar was carried out), an SEM analysis of the microstructure of the fragments of the surface of polished and etched samples, a Vickers hardness test and an analysis of the accuracy of the reproduction of the shape and roughness of the model fabricated in the DMLS procedure. A detailed analysis of the DMLS method significantly supplements the existing body of knowledge on innovative rapid prototyping techniques [1–4], and the results allow us to specify a group of aircraft structure components which may be fabricated using this method. Excellent strength properties of DMLS models and the possibility of improving surface quality by mechanical working enable the fabrication of advanced aircraft structure components operated in target conditions (under load).