Spectroscopy Based In-situ Monitoring of AlSi10Mg Repair of 7000 Series Aluminum
Open Access
Author:
Savage, Conor
Area of Honors:
Mechanical Engineering
Degree:
Bachelor of Science
Document Type:
Thesis
Thesis Supervisors:
Edward William Reutzel, Thesis Supervisor Margaret Louise Byron, Thesis Honors Advisor
Keywords:
Additive Manufacturing Laser Directed Energy Depsotion Spectroscopy Repair Aluminum 7075 Process Monitoring
Abstract:
This document delves into the complexities and opportunities associated with repairing
7000 series aluminum, an essential aerospace material utilized in lightweight structural
components, through Laser-based Directed Energy Deposition (LDED) additive manufacturing.
The aerospace sector demands materials of superior strength and resilience, leading to the
widespread use of 7000 series aluminum. However, this alloy is typically used in the heat-treated
condition, and conventional repair methods often compromise these essential properties by
reducing strength in the heat affected zone. LDED emerges as a promising alternative to
conventional arc-based repair methods, leveraging precise material deposition and thermal input
facilitated by high-powered lasers. Nonetheless, LDED repair of 7000 series aluminum presents
unique challenges, including the stochastic formation of defects such as porosity and solidification
cracking. To address these challenges, Optical Emission Spectroscopy (OES) in-situ monitoring
techniques were explored for ability to identify defect formation. The insights gleaned from this
endeavor are expected to contribute to advancements in aerospace repair technologies, potentially
leading to cost savings and operational improvements within the industry.