Print Email Facebook Twitter Additively manufactured suspension components for an F1 car Title Additively manufactured suspension components for an F1 car: Design, Simulation,Manufacturing and Testing Author Zamariola, Nicolo' (TU Delft Mechanical, Maritime and Materials Engineering) Contributor Sietsma, J. (mentor) Degree granting institution Delft University of Technology Programme Mechanical Engineering Date 2018-01-12 Abstract The recent possibilities given by additive manufacturing in free shape design have been seen as apotential breakthrough in the design and production of structural components of a racecar and moregenerally their influences on the future lightweight strategies in the automotive industry is expectedto influence the next generation of products. Among the emerging techniques for the production ofmetal products, Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) technologiesare becoming technically ahead of the competition: the possibility of direct production of aluminumand titanium alloys components with good surface finishing and net shape from CAD geometry isnowadays a concrete option for the mechanical designer.The purpose of the present study is to demonstrate the feasibility of thementionedAMtechniquesand to exploit their potentialweight saving opportunities in the design of highly structurally optimizedracing components while determining the current state-of-art of AM for metallic components. Thepresent project reports the design and production of two car components redesigned in the perspectiveof the novel manufacturing techniques.The first component is the rear top wishbone bracket of the rear suspension. The productionhas been developed following the best practices for the design of additively manufactured structuressuch as complete topology optimization and a reconstruction with special focus on the design formanufacturing assessment. The bracket has been developed for DMLS manufacturing in titaniumalloy Ti6Al4V. On the contrary, the second component has been developed in a novel aluminumalloy:the Scalmalloy, commercial name of a high strength aluminum alloy specifically developed for highstrength to weight critical applications. For this novel material a characterization campaign has beenset up comprehending tensile testing, micro-graphical analysis, tomography inspection and an X-rayanalysis. Both component underwent a full scale fatigue testing.Both components proved an achievement in terms of weight saving between 7% and 10%with thesame functionality and performance level of the machine counterparts. The material characterizationcampaign revealed the concrete maturity of the DMLS process for Ti6Al4V while the process of SLMproduction of Scalmalloy requires some final tuning. The tensile strength levels achieved are compliantfor both materials’ specifications but the presence of localized lack of fusion in the Scalmalloyspecimens reduced the final ductility of the material considerably.The obtained results are an encouraging step towards the application of the analyzed technologyin structural components for the motorsport industry and possibly, in the near future, for the widerautomotive industry. The limited standardization in the quality processes is addressed as well witha concrete proposal for establishing a controlled level of defects in additively manufactured components. Subject ScalmalloyAdditive ManufacturingSelective Laser MeltingTopology optimization To reference this document use: http://resolver.tudelft.nl/uuid:9677fc1d-8d99-4977-b7e3-4708ee7d22af Embargo date 2023-01-12 Coordinates 44.53111, 10.86278 Part of collection Student theses Document type master thesis Rights © 2018 Nicolo' Zamariola Files PDF AMed_suspension_components_NZ.pdf 60.48 MB Close viewer /islandora/object/uuid:9677fc1d-8d99-4977-b7e3-4708ee7d22af/datastream/OBJ/view