Date of Award
2024
Document Type
Dissertation
Degree Name
Doctor of Philosophy (PhD)
Department
Mechanical and Aerospace Engineering
Committee Chair
Judith A. Schneider
Committee Member
Nicholas J. Ginga
Committee Member
Nathan C. Spulak
Committee Member
Luke N. Brewer
Committee Member
Michael K. Minor
Research Advisor
Judith A. Schneider
Subject(s)
Aluminum alloys--Mechanical properties, Aluminum alloys--Ductility, Additive manufacturing
Abstract
Although the use of wrought high strength aluminum alloys is prevalent throughout aerospace systems, they often have long lead times and become difficult to source throughout the long lifecycle of aviation systems. Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM) provides opportunity to directly manufacture wrought equivalent aluminum products without forging supply chain challenges. If these LBPF components are made with the same aluminum material system with similar strength and ductility, they can be a direct replacement for traditionally manufactured components. However, existing 7xxx aluminum alloys are prone to cracking during fusion welding and therefore are not readily produced through LPBF. Therefore, a 7xxx aluminum alloy capable of LPBF with similar strength and elongation to heritage AA7075 and AA7050 for aerospace industry utility is desired. The objective of this work is to evaluate the material performance of LPBF 7A77 aluminum alloy as a substitute material for traditionally wrought 7XXX series aluminum alloy aerospace parts. This work demonstrated the 7A77 alloy can produce crack-free structures with resulting mechanical properties that exceed the wrought alloy with optimized aging heat treatments.
Recommended Citation
Gaddes, Jeffrey S., "Thermal processing of Al-Zn-Cu-Mg-Zr laser powder bed fusion material for increased ductility" (2024). Dissertations. 403.
https://louis.uah.edu/uah-dissertations/403