Metal additive manufacturing for lightweight helicopter parts

A process design and topology optimisation study was undertaken, beginning with a baseline stress analysis for a current machined-from-solid AlSi10Mg aluminium alloy handle, in order to evaluate different AM handle designs and also a hollow handle, indicating weight savings of between 20% and 45% were possible.

As part of the Digital Reconfigurable Additive Manufacturing facilities for Aerospace project, engineers at the MTC’s National Centre for Additive Manufacturing (NCAM) worked with Hyde Aero Products on two Leonardo Class III helicopter parts, as test cases for metal AM as part of a weight reduction initiative.

The forward and aft service door handles were identified as the test parts to establish how metal AM could reduce the weight of these components and whether it would offer a cost effective solution for the manufacture of these handles.

A process design and topology optimisation study was undertaken, beginning with a baseline stress analysis for a current machined-from-solid AlSi10Mg aluminium alloy handle, in order to evaluate different AM handle designs and also a hollow handle, indicating weight savings of between 20% and 45% were possible.

Test builds were undertaken to identify the optimum method and orientation for producing the parts, and NCAM engineers worked with Hyde Aero Products to develop a business case model for the handles, which could also be used for other metal AM parts in support of the new AM venture.

 

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