Laser DED additive manufacturing: Aluminium alloy tank sphere (defence / aerospace)
Industrial challenge
The challenge is to replace conventional casting with a large aluminium tank blank (Ø 1 m), while significantly reducing costs and lead times. The solution must guarantee mechanical performance compatible with defence and aerospace requirements on a large structural component.
Solution implemented
A blank is produced using wire-fed laser DED, designed directly for final machining. The process is optimised through fine-tuning of the manufacturing parameters, supplemented by numerical simulation to anticipate distortion and precisely define the required machining allowances.
Challenge met
Manufacturing requires stabilising a process on a highly reflective aluminium alloy while ensuring material homogeneity on a large spherical geometry. Controlling distortion and achieving mechanical properties that meet the requirements are the main technical hurdles to overcome.
Customer results
The blank produced is ready for machining, with controlled machining allowances of around ~2 mm. The numerical simulation was validated on a real case, confirming the robustness of the approach, and the mechanical properties obtained meet the application requirements.
