Chinese Journal of Lasers, Volume. 51, Issue 24, 2402305(2024)

Practice and Prospect of Laser Additive Manufacturing in Aerospace Field

Zhiyong Li1,2、*, Dongxue Han1,2, Shikun Jiao1,2, Quanfu Liu3, Cangrui Yu2, Yuanhong Qian1,2, Rong Chen1,2, and Yang Liu1,2
Author Affiliations
  • 1Aerospace Additive Manufacturing Technology (Beijing) Co., Ltd., Beijing 100074, China
  • 2Beijing Xinghang Electro-mechanical Equipment Co., Ltd., Beijing 100074, China
  • 3HIWING Technology Academy of CASIC, Beijing 100074, China
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    Figures & Tables(17)
    Schematic of laser additive manufacturing process and defects. (a) Interaction process between laser and raw material[26]; (b) lack of fusion[35]; (c) keyhole[36]; (d) crack[37]; (e) inconsistent melt pool[38]; (f) balling[38]
    Illustrations of wing rudders. (a) Overall morphology of lattice wing rudder; (b) lattice structure of lattice wing rudder;(c) overall morphology of honeycomb wing rudder; (d) honeycomb structure of honeycomb wing rudder
    Illustrations of brackets. (a) Momentum wheel bracket[41]; (b) antenna support of Sentinel-1 satellite[42]
    Illustrations of cabins. (a) Barrel cabin; (b) irregular cabin
    LAM engine
    Illustrations of heat-proof outsole frame of re-entry capsule[47]. (a) Schematic of heat-proof outsole frame of re-entry capsule; (b) heat-proof outsole frame of re-entry capsule
    Working diagram of selective laser melting equipment[51-52]
    Diagram offield mirror format[54]
    Extension of format by moving galvanometer[56]
    Illustrations of multibeam splicing. (a) Schematic of extension of format by multibeams[57]; (b) schematic [54]
    Laser melting deposition equipment[59-60]
    Laser melting deposition equipment with manipulator[61]
    Principle diagram of laser five-axis additive manufacturing and subtractive manufacturing process[21]
    Layout of additive manufacturing demonstration production line
    Demonstration of additive manufacturing production line
    • Table 1. Typical aerospace components

      View table

      Table 1. Typical aerospace components

      Structure typeComponentApplication scenarioRequirementStructural featureCommonly used material

      Light-

      weight structure

      Wing

      rudder

      Pneumatic components: affect thrust of space equipment and aerodynamic liftLight weight, heat dissipation, and high heat intensity

      Exterior: thin wall;

      Interior: honeycomb,

      lattice core

      Titanium alloy and high-temperature alloy
      BracketBearing components: support load, fix connected structure, and active separationLight weight, high structural stiffness, and high structural strength

      Thin wall + lattice,

      thin wall + stiffening rib

      Aluminum alloy and titanium alloy
      Structure- function integrated structureCabinTemperature resistant and bearing components: installation and support platform of core systemHigh structural stiffness and high thermal strength“Skin diaphragm + stiffening rib” structure with characteristics of closed cavity, slot or open cavityAluminum alloy, titanium alloy, and high-temperature alloy

      Engine

      Power components: provide thrust to propel spacecraft motionHigh thrust-weight ratio, light weight, heat resistance, and high fatigue life

      Complex component with pipes, blade, and nozzles

      Titanium alloy and high-temperature alloy
      Large monolithic structureFrameBearing components: bear load to ensure structural stability and safetyHigh specific strength

      “Thin-panel +

      stiffening rib” structure; shape is up to meters and thickness is in order of 100 mm

      Titanium alloy
    • Table 2. Large-size selective laser melting equipments

      View table

      Table 2. Large-size selective laser melting equipments

      No.ManufacturerEquipment modelForming dimension /(mm×mm×mm)Laser quantity
      1EOSM400-4400×400×4004
      2GE additiveConcept Laser X Line 2000R800×400×5002
      3Aerospace Additive Manufacturing Technology (Beijing) Co., Ltd.ASA-1200M1200×600×15008
      ASA-800M800×600×10004

      ASA-530M

      (production line)

      530×530×6704
      4BLTBLT-S15001500×1500×120026
      5Farsoon TechnologiesFS1521M-U1530×1530×165016
      FS1211M1330×700×17008/10
      6E-Plus-3DEP-M12501250×1250×12509
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    Zhiyong Li, Dongxue Han, Shikun Jiao, Quanfu Liu, Cangrui Yu, Yuanhong Qian, Rong Chen, Yang Liu. Practice and Prospect of Laser Additive Manufacturing in Aerospace Field[J]. Chinese Journal of Lasers, 2024, 51(24): 2402305

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    Paper Information

    Category: Laser Additive Manufacturing

    Received: Mar. 15, 2024

    Accepted: Jun. 21, 2024

    Published Online: Dec. 9, 2024

    The Author Email: Li Zhiyong (lzy0231@sina.com)

    DOI:10.3788/CJL240687

    CSTR:32183.14.CJL240687

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