PSI - Issue 53

Stefania Franchitti et al. / Procedia Structural Integrity 53 (2024) 397–406 Author name / Structural Integrity Procedia 00 (2019) 000 – 000

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4. Conclusions In this work, the qualification of the additive manufactured support attachments for the BFA of the SPACE RIDER re-entry vehicle has been described. The EBM process was chosen as AM technology to produce the components in Ti6Al4V Titanium alloy. The qualification activities were performed according to a building block approach suggested by ESA standard, starting on powder level, moving to a specimen level and concluding at prototype level (static and thermomechanical tests). The tests at prototypes level were performed more times on the same test article in order to assess the reusability of the body flap support in sustaining more than one re-entry flight. The qualification procedure successfully demonstrated that the EBM technology was an appropriate choice for this type of space application allowing to reduce manufacturing costs and ensuring a high thermo-structural strength of the manufactured components. Acknowledgements This research was supported by European Space Agency within the context of SPACE RIDER program. References Arcella, F., Froes, F.H., 2000. Producing titanium aerospace components from powder using laser forming. JOM, 52, 28 – 30. Blakey-Milner, B., Gradl, P., Snedden, G., Brooks, M., Pitot, J., Lopez, E., Leary, M., Berto, F., du Plessis, A., 2021. Metal additive manufacturing in aerospace: A review, Materials & Design, 209, 110008. Borrelli, R., Franchitti, S., Pirozzi, C., Carrino, L., Nele, L., Polini, W., Sorrentino, L., Corrado, A., 2020. Ti6Al4V Parts Produced by Electron Beam Melting: Analysis of Dimensional Accuracy and Surface Roughness, Journal of Advanced Manufacturing Systems, 19(1), 1 – 24. Debnath, B., Shakur, M.S., Tanjum, F., Rahman, M.A., Adnan, Z.H., 2022. Impact of Additive Manufacturing on the Supply Chain of Aerospace Spare Parts Industry — A Review. Logistics 2022, 6, 28. Deppe, G, Koch, R. 2014. Exploring the influence on an additive manufacturing integration on future MRO processes in aeronautics. In: RapidTech. UniversitätPaderborn. Fedele, A., Guidotti, G., Rufolo, G., Malucchi, G., Denaro, A., Massobrio, F., Dussy, S., Mancuso, S., Tumino, G., 2018. The Space Rider Programme: End user's needs and payload applications survey as driver for mission and system definition, Acta Astronautica, 152, 534-541. Franchitti, S., Pirozzi, C., Borrelli, R., (2020). Influence of hot isostatic pressing and surface finish on the mechanical behaviour of Ti6Al4V processed by electron beam melting. Fatigue and fracture of engineering materials and structures, 1-14. Gardi, R., Pezzella, G., Franchitti, S., Borrelli, R., Pirozzi, C., Quaranta, V., Tiseo, B., Bruno, G., 2017. Additive Layer Manufacturing for Entry Capsules, 68th International Astronautical Congress, IAC2017, Adelaide, Australia, September 25-29. Koerner, C., 2016. Additive manufacturing of metallic components by selective electron beam melting - A review. Int. Mater. Rev. 61(5), 361 – 377. Pant, M., Pidge, P., Nagdeve, L., Kumar, H., 2021. A review of additive manufacturing in aerospace application. Revue des Composites et des Matériaux Avancés-Journal of Composite and Advanced Materials, 31(2), 109-115. Pirozzi, C., Borrelli, R., Franchitti, S., Caiazzo, F., Alfieri, V., Argenio, P., 2017. Study on the Factors Affecting the Mechanical Behavior of Electron Beam Melted Ti6Al4V, Journal of Materials Engineering and Performance, 26(9) Pirozzi, C., Franchitti, S., Borrelli, R., Diodati, G., Vatasso, G., 2019. Experimental Study on the Porosity of Electron Beam Melting-Manufactured Ti6Al4V, Journal of Materials Engineering and Performance, 28 (5), 2649-2660. Pirozzi, C., Franchitti, S., Borrelli, R., Chiariello, A., Di Palma, L., 2020. The Effect of Post-Processing on the Mechanical Behavior of Ti6Al4V Manufactured by Electron Beam Powder Bed Fusion for General Aviation Primary Structural Applications. Aerospace 2020, 7, 75. Portolés, L., Jordá, O., Jordá, L., Uriondo, A., Esperon-Miguez, M., Perinpanayagam, S., 2016. A qualification procedure to manufacture and repair aerospace parts with electron beam melting, Journal of Manufacturing Systems, 41, 65-75. Seifi, M., Salem, A., Beuth, J., Harrysson, O., Lewandowski, J.J., 2016. Overview of materials qualification needs for metal additive manufacturing. JOM, 68, 747 – 764. Silvestri, A.T., Foglia S., Borrelli R., Franchitti, S., Pirozzi, C., Astarita, A., 2020. Electron beam melting of Ti6Al4V: Role of the process parameters under the same energy density, Journal of manufacturing process, 60, 162-179.