Characterization and Optimization of Corrosion Resistance in 3D Printed Metal Alloys for Aerospace Applications

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.