Hybrid Experimental-Numerical Approach for AM Component Certification

The use of Additive Manufacturing (AM) in the aerospace industry can revolutionize component design and production, offering significant advantages in terms of flexibility and on-demand manufacturing. However, the applicability of AM components for critical applications requires rigorous experimental and numerical validation of their mechanical properties and reliability. The ACARMA project (co-funded by the Italian Ministry of Defense under contract No. 8732 of Rep. dated 13.12.2019 – ACARMA PNRM a2017.079) proposes a methodology to integrate experiments and numerical simulation to predict the failure conditions of aerospace components manufactured via AM, with the aim of reducing both the time and cost of the certification process. The project was divided into two consecutive phases. The first, focused on material-level, saw the characterization of SLM AlSi10Mg with more than 200 tests which led to the development of an advanced material model, implemented in LSDyna, that accounts for the influence of strain rate and temperature (Johnson-Cook), process-induced anisotropy and asymmetry (Cazacu-Barlat 2004) and triaxiality and shear effects on damage (PDSC model). The second phase advanced to the component level, applying Design-for-Additive Manufacturing to the Scoop Fairing of the Leonardo M346 aircraft. This complex component underwent extensive qualification tests, validating the proposed methodology in real-world scenarios, such as bird strike impact.