Thesis Abstract

Abstract
The aerospace industry is constantly seeking innovative solutions to enhance the performance and durability of materials used in aircraft components. This thesis focuses on the characterization and optimization of corrosion resistance in 3D printed metal alloys for aerospace applications. The rapid advancement of additive manufacturing technologies has opened up new possibilities for creating complex geometries and customized parts with improved mechanical properties. However, the susceptibility of these materials to corrosion poses a significant challenge that must be addressed to ensure the long-term reliability of aerospace structures. Chapter One provides an introduction to the research topic, including the background of the study, problem statement, objectives, limitations, scope, significance, structure of the thesis, and definitions of key terms. The chapter sets the stage for understanding the importance of investigating corrosion resistance in 3D printed metal alloys for aerospace applications. Chapter Two presents a comprehensive literature review covering ten key areas related to corrosion behavior, additive manufacturing techniques, material selection, surface treatments, corrosion testing methods, alloy compositions, design considerations, environmental factors, protective coatings, and case studies of corrosion in aerospace components. This review synthesizes existing knowledge and identifies gaps in the current understanding of corrosion resistance in 3D printed metal alloys. Chapter Three outlines the research methodology, detailing the experimental procedures, materials and equipment used, sample preparation techniques, corrosion testing protocols, data analysis methods, and validation strategies. Eight key components of the methodology are discussed to ensure a systematic and rigorous approach to investigating the corrosion behavior of 3D printed metal alloys. Chapter Four presents a detailed discussion of the findings obtained from the experimental investigations, including the characterization of corrosion mechanisms, identification of critical factors influencing corrosion resistance, evaluation of surface treatments and coatings, comparison of different alloy compositions, analysis of environmental effects, and recommendations for optimizing corrosion resistance in 3D printed metal alloys for aerospace applications. The chapter offers insights into the complex interactions between material properties, processing parameters, and environmental conditions that affect corrosion performance. Chapter Five concludes the thesis by summarizing the key findings, highlighting the significance of the research outcomes, discussing the implications for the aerospace industry, proposing future research directions, and emphasizing the importance of addressing corrosion challenges in additive manufacturing of metal alloys for aerospace applications. The thesis contributes to advancing the knowledge and understanding of corrosion resistance in 3D printed metal alloys, offering valuable insights for improving the reliability and safety of aerospace structures. Keywords corrosion resistance, 3D printing, metal alloys, aerospace applications, additive manufacturing, material characterization, optimization, surface treatments, environmental factors.

Thesis Overview

The project titled "Characterization and Optimization of Corrosion Resistance in 3D Printed Metal Alloys for Aerospace Applications" aims to address the critical issue of corrosion in 3D printed metal alloys used in aerospace applications. With the increasing adoption of additive manufacturing techniques in the aerospace industry, understanding and enhancing the corrosion resistance of these materials is essential for ensuring the long-term reliability and safety of aerospace components. The research will begin with a comprehensive literature review to explore the current state of knowledge regarding corrosion resistance in metal alloys, particularly those produced using 3D printing technologies. This review will provide a foundation for understanding the factors that influence corrosion behavior in these materials, including microstructure, composition, processing parameters, and environmental conditions. Following the literature review, the research will focus on characterizing the corrosion behavior of specific 3D printed metal alloys commonly used in aerospace applications. Experimental methods such as electrochemical testing, surface analysis techniques, and accelerated corrosion testing will be employed to evaluate the corrosion resistance of these materials under different conditions. Moreover, the project will involve optimizing the corrosion resistance of 3D printed metal alloys through the design of novel alloy compositions, surface treatments, and protective coatings. By systematically studying the effects of various factors on corrosion performance, the research aims to develop strategies for enhancing the durability and longevity of aerospace components fabricated using additive manufacturing techniques. The outcomes of this research are expected to contribute significantly to the field of materials science and metallurgical engineering by providing insights into the corrosion behavior of 3D printed metal alloys and offering practical solutions for improving their resistance to corrosion. Ultimately, the findings from this study have the potential to inform the development of more robust and reliable aerospace materials, thereby advancing the safety and performance of aerospace systems in the future.