Application of high-tech aluminum alloy VAS1 for additive manufacturing of helicopter parts
Benarieb I., Savichev I.D., Khasikov D.V., Denisov A.M. Application of high-tech aluminum alloy VAS1 for additive manufacturing of helicopter parts // Proceedings of VIAM. 2025. No. 10. DOI: 10.18577/2307-6046-2025-0-10-52-67. URL: https://test.viam.ru/en/journal/2025/10/5
Keywords
additive technologies, selective laser melting, weight efficiency, topology optimization, mechanical properties, porosity, roughness, X-ray computed tomography
Abstract
The study presents the results of research on the development of advanced high-tech aluminum alloy VAS1 for production of helicopter parts by selective laser melting (SLM). The effect of SLM process parameters on material quality, including microstructure, porosity and roughness has been investigated. Experimental data on the mechanical properties of the material in the as-built state and after strengthening heat treatment are presented. A prototype bracket-type part has been successfully fabricated meeting all geometric tolerances and being free from critical defects.
Reference list
- Kablov E.N., Evgenov A.G., Bakradze M.M. et al. New-generation materials and digital additive technologies for the production of resource parts by FSUE VIAM. Part 1. Materials and synthesis technologies. Elektrometallurgiya, 2022, no. 1. pp. 2–12.
- Kablov E.N., Evgenov A.G., Bakradze M.M. et al. New-generation materials and digital additive technologies for the production of resource parts by FSUE VIAM. Part 2. Compensation and control of deviations, GIP and heat treatment. Elektrometallurgiya, 2022, no. 2, pp. 2–12.
- Kablov E.N., Evgenov A.G., Petrushin N.V. et al. New generation materials and digital additive technologies for the production of resource parts FSUE «VIAM». Part 3. Adaptation and creation of materials. Elektrometallurgiya, 2022, no. 4, pp. 15–25.
- Zakharov V.V. Aluminum alloys for additive technologies. Metallovedenie i termicheskaya obrabotka metallov, 2021, no. 5 (791), pp. 3–8.
- Ryabov D.K., Grushin I.A., Seferyan A.G. Some features of the formation of the structure and properties of new aluminum alloys in additive manufacturing. Stankoinstrument, 2022, no. 1 (26), pp. 44–51.
- Popkova I.S., Zolotorevsky V.S., Solonin A.N. Production of products from aluminum and its alloys by selective laser melting. Tekhnologiya legkikh splavov, 2015, no. 4, pp. 14–24.
- Zhu Z., Hu Z., Li H. et al. Recent progress on the additive manufacturing of aluminum alloys and aluminum matrix composites: Microstructure, properties, and applications. International Journal of Machine Tools and Manufacture, 2023, vol. 190, p. 104047.
- Montanari R., Palombi A., Richetta M., Varone A. Additive manufacturing of aluminum alloys for aeronautic applications: Advantages and problems. Metals, 2023, vol. 13, no. 4, p. 716.
- Rometsch P., Jia Q., Yang K.V., Wu X. Aluminum alloys for selective laser melting-towards improved performance. Additive Manufacturing for the Aerospace Industry. Elsevier, 2019, pр. 301–325.
- Blakey-Milner B., Du Plessis A., Gradl P. et al. Metal additive manufacturing in aerospace: a review. Materials & Design, 2021, vol. 209, p. 110008.
- Bakradze M.M., Rogalev A.M., Sukhov D.I., Aslanyan G.G. Features of surface formation by selective laser melting. Metallovedenie i termicheskaya obrabotka metallov, 2022, no. 2 (800), pp. 40–48.
- Sukhov D.I., Nerush S.V., Belyakov S.V., Mazalov P.B. Study of surface layer roughness parameters and manufacturing accuracy of additive manufacturing products. Izvestiya vuzov. Mashinostroyenie, 2017, no. 9 (690), pp. 73–84.
- Ivanova A.O., Zavodov A.V., Dynin N.V., Fomina M.A. Efficiency of complex alloying AlSi10Mg type alloy with transition metals for selective laser melting technologies. Trudy VIAM, 2017, no. 7 (55), paper no. 1. Available at: http://www.viam-works.ru (accessed: May 16, 2024). DOI: 10.18577/2307-6046-2017-0-7-1-1.
- Dynin N.V., Zavodov A.V., Oglodkov M.S., Khasikov D.V. The influence of process parameters of selective laser melting on the structure of aluminum alloy Al–Si–Mg system. Trudy VIAM, 2017, no. 10 (58), paper no. 01. Available at: http://www.viam-works.ru (accessed: May 16, 2024). DOI: 10.18577/2307-6046-2017-0-10-1-1.
- Dynin N.V., Antipov V.V., Khasikov D.V., Benarieb I., Zavodov A.V., Evgenov A.G. Structure and mechanical properties of an advanced aluminium alloy AlSi10MgCu (Ce, Zr) produced by selective laser melting. Materials Letters, 2021, vol. 284, art. 128898. DOI: 10.1016/j.matlet.2020.128898.
- Kozlov I.A., Volkov I.A., Fomina M.A., Zakharov K.E. Features of chemical oxidation of semi-finished products obtained by selective laser melting from a metal powder composition of the alloy VAS1. Trudy VIAM, 2023, no. 11 (129), paper no. 09. Available at: http://www.viam-works.ru (accessed: February 11, 2024). DOI: 10.18577/2307-6046-2023-0-11-90-98.
- Benarieb I., Dynin N.V., Kuznetsova P.E., Sbitneva S.V. Changes in the structure and mechanical properties during heat treatment of aluminum alloy AlSi10MgCu obtained by selective laser melting. Tekhnologiya legkikh splavov, 2023, no. 4, pp. 5–18.
- Shchetinina N.D., Kuznetsova P.E., Dynin N.V., Selivanov A.A. Aluminum alloys with additions of Sc and Zr in additive manufacturing (review). Aviation materials and technologies, 2021, no. 3 (64), paper no. 03. Available at: http://www.journal.viam.ru (accessed: May 14, 2024). DOI: 10.18577/2713-0193-2021-0-3-19-34.
- Sbitneva S.V., Zaytsev D.V., Benarieb I. Features of the structure of age-hardenable aluminum alloy AlSi10MgCu produced by selective laser melting. Trudy VIAM, 2024, no. 9 (139), paper no. 03. Available at: http://www.viam-works.ru (accessed: December 21, 2024). DOI: 10.18577/2307-6046-2024-0-9-15-24.
- Knyazev A.E., Vostrikov A.V. Sieving of powders additive and powder manufacturings (review). Trudy VIAM, 2020, no. 11 (93), paper no. 02. Available at: http://www.viam-works.ru (accessed: October 20, 2023). DOI: 10.18577/2307-6046-2020-0-11-11-20.
- Galinovsky A.L., Golubev E.S., Kobernik N.V., Filimonov A.S. Additive technologies in the production of aerospace products: a textbook for universities. Moscow: Yurait, 2020, 115 p.
- Zlenko M.A. Additive technologies in mechanical engineering: a manual for engineers. Moscow: NAMI, 2015, 220 p.
- Morozova L.V., Raevskikh A.N. Study of defects in metallic materials obtained by selective laser melting using microscopy methods. Vestnik mashinostroyeniya, 2019, no. 10, pp. 74–79.
- Movenko D.A., Shurtakov S.V. Microcrack formation and controlling in nickel superalloys processed by selective laser melting (review). Aviation materials and technologies, 2022, no. 2 (67), paper no. 04. Available at: http://www.journal.viam.ru (accessed: April 20, 2023). DOI: 10.18577/2713-0193-2022-0-2-43-51.
- Lapteva M.A., Belova N.A., Raevskih A.N., Filonova E.V. Dependence of roughness, surface morphology structure and number of defects on the power of the laser, scanning speed and the type of hatching in the high-temperature alloys synthesized by SLS. Trudy VIAM, 2016, no. 9 (45), paper no. 09. Available at: http://www.viam-works.ru (accessed: March 17, 2024). DOI: 10.18577/2307-6046-2016-0-9-9-9.
- Karavaev A.K., Puchkov Yu.A. Study of the structure and properties of the AlSi10Mg alloy obtained by selective laser melting. Vestnik MGTU im. N.E. Baumana. Ser.: Mashinostroyenie, 2020, no. 5 (134), pp. 71–85.
- Grigoryants A.G., Kolchanov D.S., Drenin A.A., Denezhkin A.O. Influence of the main parameters of the selective laser melting process on the stability of the formation of single tracks when growing products from copper alloys. Izvestiya vuzov. Mashinostroyenie, 2019, no. 6 (711), pp. 20–29.
- Vanzetti M., Virgillito E., Aversa A. et al. Short heat treatments for the F357 aluminum alloy processed by laser powder bed fusion. Materials, 2021, vol. 14, no. 20, p. 6157.
- Yang K.V., Rometsch P., Davies C.H.J. et al. Effect of heat treatment on the microstructure and anisotropy in mechanical properties of A357 alloy produced by selective laser melting. Materials & Design, 2018, vol. 154, pp. 275–290.
- Lorusso M., Trevisan F., Calignano F. et al. A357 Alloy by LPBF for industry applications. Materials, 2020, vol. 13, no. 7, p. 1488.
- Pereira J.C., Gil E., Solaberrieta L. et al. Comparison of AlSi7Mg0.6 alloy obtained by selective laser melting and investment casting processes: Microstructure and mechanical properties in as-built/as-cast and heat-treated conditions. Materials Science and Engineering: A, 2020, vol. 778, p. 139124.
- Ponnusamy P., Rashid R.A.R., Masood S.H. et al. Mechanical properties of SLM-printed aluminium alloys: a review. Materials, 2020, vol. 13, no. 19, pp. 4301–4351.
- Aviation materials: a reference book in 13 volumes. Ed. E.N. Kablov. 7th ed., rev. and add. Moscow: VIAM, vol. 4: Aluminum and beryllium alloys, part 2: Cast aluminum alloys and beryllium-based alloys, 2008, pp. 58–59.
- Kablov E.N. The strategic directions of development of materials and technologies of their processing for the period to 2030. Aviacionnye materialy i tehnologii, 2012, no. S, pp. 7–17.
- Kablov E.N. Innovative developments of FSUE «VIAM» SSC of RF on realization of «Strategic directions of the development of materials and technologies of their processing for the period until 2030». Aviacionnye materialy i tehnologii, 2015, no. 1 (34), pp. 3–33. DOI: 10.18577/2071-9140-2015-0-1-3-33.
- Benarieb I., Savichev I.D., Khasikov D.V., Oglodkov M.S. Experience in manufacturing helicopter parts by selective laser melting from aluminum alloy VAS1. Proc. IX All-Rus. Sc. and Tech. Conf. «Problems and Prospects for the Development of Aviation, Ground Transport and Energy (ANTE-2024)». Kazan, 2024, pp. 61–62.
