Additive Manufacturing Parameters and Fatigue Strength across Aerospace Bracket Prototypes
Keywords:
Additive Manufacturing, Fatigue Strength, Aerospace Brackets, Process Parameters, Titanium AlloysAbstract
The aerospace industry increasingly relies on additive manufacturing technologies to produce complex, weight-optimized structural components such as brackets. However, the application of these components in fatigue-critical environments remains limited by the inherent uncertainties associated with the manufacturing process. This paper presents a comprehensive experimental analysis of how specific additive manufacturing parameters influence the fatigue strength of aerospace bracket prototypes fabricated from titanium alloys. By systematically varying laser power, scanning speed, and layer thickness, the study investigates the microstructural evolution, defect generation, and surface roughness of the manufactured prototypes. The research explores the direct correlation between these process-induced characteristics and the resulting high-cycle fatigue performance under simulated operational loads. Through rigorous mechanical testing and fractographic analysis, the study identifies critical parameter thresholds that minimize detrimental porosity and optimize microstructural integrity. The findings demonstrate that careful calibration of energy density inputs can significantly enhance the fatigue life of additively manufactured brackets, bridging the gap between rapid prototyping and end-use aerospace applications. This research provides a foundational understanding for engineers seeking to qualify additively manufactured load-bearing components for commercial and military aircraft, ultimately contributing to more sustainable and efficient aerospace engineering practices.References
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