Application of Ti64 Multi-Laser Powder Bed Fusion in Next Generation Actuation Systems: Selection and Analysis of Candidate Structural Part

Abstract

In a bid to increase additive manufacturing (AM) technology readiness, this study researched feasibility of AM technology application in the next generation secondary flight control systems. Taking a state-of-the-art certification framework and technology into account, a selection tool was created and used to survey the high lift and thrust reverser systems for the most suitable demonstrator part. A thrust reverser lever, the selected part was then redesigned to prove the AM technology benefits, for which a trade-off of 4 different designs and existing part was performed. The final concept showed a part count and weight reduction, which on a system level is negligible. Using analytical and numerical methods, technical feasibility of the design was proven. Nevertheless, while satisfactory, for future products a more sophisticated fatigue assessment method would be required if parts in more demanding load environments are to be considered. The recurring cost model for AM developed in the study has shown reduction in cost of the concept when compared to the existing components produced in a low-cost country. However, the AM business case is compromised when analysed against the true existing parts’ cost. Consequently, the research has shown that while the small low risk components are technically feasible and cost-competitive for AM production, the more radical technology application is needed to provide a step change in performance.