DOI: 10.18503/1995-2732-2026-24-2-115-126
Abstract
Problem Statement (Relevance). The implementation of additive manufacturing technologies in industrial production requires ensuring high productivity while maintaining consistently high product quality. Direct Laser Deposition (DLD) is a promising technology for manufacturing large-scale components with complex geometries from powder materials in the aerospace industry, enabling the replacement of conventional manufacturing approaches. This technology belongs to the class of metal additive manufacturing methods based on directed energy and material deposition. However, the DLD process is highly sensitive to technological parameters, which may lead to variations in physical and mechanical properties and the formation of defects such as porosity. Existing post-process inspection methods for finished products do not allow prediction and prevention of defect formation and are often economically inefficient. Objectives. The research is aimed at analyzing the cause-and-effect relationships leading to pore formation in order to ensure the guaranteed quality of large-scale products manufactured by Direct Laser Deposition. Methods Applied. It is the integrated quality management of components based on system and process approaches using quality management tools, including the Ishikawa diagram, Gantt chart, Measurement System Analysis (MSA), and metrological support of production processes. Originality. It lies in the application of an integrated quality management approach throughout all stages of the life cycle of large-scale products (with diameters exceeding 2000 mm and heights exceeding 1500 mm), aimed at ensuring the required quality and determining optimal technological parameters for the DLD process. Result. The paper presents the results of an experimental study on the influence of process parameters on the properties of products manufactured from RS-320 aluminum powder. Based on the conducted research and recommended processing conditions, an aircraft structural shell in the form of a thin-walled hollow cylinder with waffle-type stiffening ribs was fabricated using the Direct Laser Deposition process. Practical Relevance. DLD expands technological and design capabilities through a significant increase in productivity (approximately tenfold), the ability to manufacture large-scale components with complex geometries, process automation, improved service properties of finished products, and weight reduction while maintaining strength characteristics. The implementation of comprehensive quality control at all stages of production ensures stable and guaranteed product quality.
Keywords
Direct Laser Deposition (DLD), quality management of large-scale metal products, Ishikawa diagram, Gantt chart, Measurement System Analysis (MSA).
For citation
Mikheeva N.V., Timofeev A.N., Logacheva A.I., Baskov F.A., Voeyko O.A. On the Quality of Large-Scale Complex-Shaped Aluminum Alloy Components Manufactured by Direct Laser Deposition. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2026, vol. 24, no. 2, pp. 115-126. https://doi.org/10.18503/1995-2732-2026-24-2-115-126
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