Metal Additive Manufacturing For Lightweight Aerospace Structural Components

Abstract

Metal additive manufacturing (AM) is transforming aerospace engineering by enabling the fabrication of geometrically complex, lightweight structural components that are impossible to produce through conventional manufacturing. This paper investigates the mechanical performance of laser powder bed fusion (LPBF) processed aerospace alloys—Ti-6Al-4V, Inconel 718, and AlSi10Mg—focusing on tensile properties, fatigue behavior, and the influence of post-processing treatments. Topology-optimized bracket designs achieved weight reductions of 52-75% while maintaining structural integrity under flight loads. LPBF specimens subjected to hot isostatic pressing (HIP) exhibited ultimate tensile strengths exceeding wrought equivalents by 8-14% and fatigue lives comparable to or exceeding conventional materials. Process-structure-property relationships were established through comprehensive microstructural characterization using electron backscatter diffraction (EBSD), micro-computed tomography (µ-CT), and fractography. The results validate LPBF as a viable production route for flight-critical aerospace components, provided appropriate post-processing and quality assurance protocols are implemented.