Thesis Abstract

Abstract
Additive manufacturing (AM) has revolutionized the production of complex components in various industries, including aerospace, automotive, and healthcare. This study focuses on the performance evaluation of AM techniques for producing high-strength aluminum alloys. Aluminum alloys are widely used in engineering applications due to their excellent strength-to-weight ratio and corrosion resistance. However, traditional manufacturing processes such as casting and machining may have limitations in achieving complex geometries and optimal material properties. AM offers the potential to overcome these limitations by enabling the fabrication of intricate designs with tailored properties. The objective of this research is to investigate the capabilities and limitations of different AM techniques, such as selective laser melting (SLM), electron beam melting (EBM), and binder jetting, in producing high-strength aluminum alloys. A comprehensive literature review is conducted to understand the current state of the art in AM of aluminum alloys, including the influence of process parameters on material properties and microstructure. The research methodology includes experimental work to fabricate aluminum alloy specimens using SLM and EBM, followed by mechanical testing to evaluate their tensile strength, hardness, and microstructural characteristics. The findings of this study reveal the influence of AM process parameters, such as laser power, scanning speed, and powder bed temperature, on the mechanical properties of aluminum alloys. The microstructural analysis shows the presence of fine equiaxed grains and intermetallic phases, which contribute to the enhanced strength of the AM-produced parts. Furthermore, the discussion of results highlights the importance of post-processing treatments, such as heat treatment and hot isostatic pressing, in improving the mechanical performance of AM-fabricated aluminum components. In conclusion, this research contributes to the understanding of AM techniques for producing high-strength aluminum alloys and provides insights into optimizing process parameters to achieve desired material properties. The significance of this study lies in the potential applications of AM in manufacturing lightweight, high-performance components for various industrial sectors. Future research directions may focus on further enhancing the mechanical properties of AM-produced aluminum alloys through advanced process monitoring and optimization strategies.

Thesis Overview

The project titled "Performance Evaluation of Additive Manufacturing Techniques for Producing High-Strength Aluminum Alloys" aims to investigate and assess the efficacy of various additive manufacturing techniques in producing high-strength aluminum alloys. The research focuses on leveraging the capabilities of additive manufacturing, also known as 3D printing, to enhance the mechanical properties and performance of aluminum alloys, which are widely used in industries such as aerospace, automotive, and manufacturing. Aluminum alloys are favored for their lightweight properties and high strength-to-weight ratio, making them essential materials in modern engineering applications. However, traditional manufacturing processes may have limitations in achieving complex geometries and optimized material properties. Additive manufacturing offers unique advantages in producing intricate designs with improved mechanical properties by layering material in a controlled manner. The study will begin with a comprehensive literature review to explore the current state-of-the-art additive manufacturing techniques for aluminum alloys. This review will cover aspects such as material selection, process parameters, post-processing methods, and the mechanical properties of additively manufactured aluminum components. By analyzing existing research and case studies, the project aims to identify the strengths and limitations of different additive manufacturing methods in enhancing the strength and performance of aluminum alloys. The research methodology will involve experimental investigations to validate the findings from the literature review. Various additive manufacturing techniques, such as selective laser melting (SLM), electron beam melting (EBM), and binder jetting, will be employed to fabricate high-strength aluminum alloy samples. The fabricated samples will undergo thorough mechanical testing, including tensile, compression, and fatigue tests, to evaluate their performance under different loading conditions. Furthermore, the project will assess the microstructural characteristics of the additively manufactured aluminum alloys using advanced microscopy techniques. The microstructural analysis will provide insights into the grain structure, porosity, and phase distribution within the samples, which directly influence the mechanical properties of the material. The discussion of findings will involve a detailed analysis of the experimental results, comparing the mechanical properties of additively manufactured aluminum alloys with conventionally processed materials. The study aims to identify the optimal additive manufacturing technique that can produce high-strength aluminum alloys with enhanced mechanical properties suitable for demanding applications in various industries. In conclusion, the research on the performance evaluation of additive manufacturing techniques for producing high-strength aluminum alloys holds significant implications for advancing the utilization of aluminum alloys in critical engineering applications. By optimizing the additive manufacturing process parameters and material compositions, this study aims to contribute valuable insights to enhance the performance and reliability of aluminum components in industrial settings.