Development on shape and performance control of aeronautical parts in additive manufacturing

The strong thermal-solidification-mechanical coupling in the additive manufacturing process makes it technically difficult to establish a reliable shape accuracy and performance control method in aerospace applications. Most of the existing shape and performance control methods are aimed at improving shape accuracy and mechanical performance separately. To understand the development trend of shape accuracy and performance control, this study reviews the progress covering mechanism analysis of shape and performance defects, prediction and compensation methods, process control, different assisted machining methods, application effects, heat-treat. The shape and surface defects are mainly caused by the design method and the instability of the molten pool and the high cooling rate during manufacturing process, and the mechanical performance defects are mainly formed by the special microstructure and internal defects formed during the manufacturing process. Before manufacturing, the shape and surface defects are predicted and compensated mainly by simulation and preheating. In the processing stage, key process parameters are controlled to ensure constant heat input and stability of the molten pool. Auxiliary technology and post-processing are important methods to optimize surface quality and microstructure to enhance shape accuracy and performance. The current deficiencies and future challenges of shape and performance collaborative control are summarized to lay the foundation for the further development of shape accuracy and performance control in AM.