Institution news
Q: Please can you briefly explain your role and involvement with structural integrity of advanced manufactured materials/assets?
Xiang Zhang (XZ): My involvement with advanced manufactured materials began 20 years ago on the application of the friction stir welding technology for the aerospace structures. My research ranged from performing fatigue testing of welded aluminium joints to development of fracture mechanics based modelling and predictive methods for damage tolerance design. Since 2013, I’ve been working on the additive manufacturing (AM) technology, with a focus on high strength titanium alloys, investigating the effect of process induced defects on fatigue strength, and the influence of microstructure and residual stress on fatigue crack behaviour.
Q: What is the number one challenge for adopting new testing methods for advanced manufactured assets?
XZ: From the perspective of structural integrity of additive manufactured materials, the primary challenge faced by those adopting the technology is the need for establishing “powder-process-structure-property-performance” relationships in the new testing and analysis framework. This requirement did not exist for the conventionally processed materials, as conventional materials and structures/assets are qualified at two separate stages, i.e. materials first and then structural parts. For additive manufacturing, we build material and structure in one single process, as often being referred as the near-net shape 3D printing.
Q: What is the most exciting development in this field at the moment, either within your company or in the industry in general?
XZ: From my perspective, the fast rate of development of additive manufacturing in the industry is demonstrated by the overwhelmingly large and increasing numbers of research and development projects in recent years. In the structural integrity area, research activities span from the raw material qualification, microstructure and texture characterisation, through to the mechanical performance. The recent developments in both imaging technologies and sophisticated numerical modelling methods have provided a much more rigorous and ultimately more fruitful approach to optimise the structural integrity of additive manufactured parts.
Q: Where do you see the future of the industry in the next five years?
XZ: Expanding on the previous question, I personally see all the current research efforts on structural integrity of AM materials will contribute to the material qualification and certification, to realise the industrial adoption of AM materials in safety critical components.
Q: Please can you say what key things that attendees can expect learn from your presentation?
XZ: My presentation shall provide an overview of the current development of structural integrity of additive manufactured titanium for the Aerospace sector, and highlight some key challenges for structural integrity assessment. Through a summary of our recent work, attendees can expect an insight into the effects of process induced defects on the fatigue strength, and the influence of microstructure and residual stress on fatigue crack behaviour. These material properties are directly related to the durability and damage tolerance performance of structures.
Q: What other topics are you looking forward to hearing about and discussing at the upcoming seminar?
XZ: I am looking forward to all presentations in the programme as they are relevant to my research, in particular the talks on the regulators perspective, the NDE requirements and standards, and the process-structure-property relationships for Additive Manufactured parts.
Q: Why do you feel it is important for all professionals to join this seminar?
XZ: In my experience it is vital to share information and experiences, for knowledge transfer among the engineering and research community for successful innovation and adoption of new technologies. Cross-discipline and cross-sector knowledge, and communications among the academia and industry are very valuable in the application of new technologies.
Optimising Structural Integrity: Advanced Manufacturing, Materials Development and Analysis Methods takes place on 5 November 2019 at One Birdcage Walk, London.
Attendees will gain a clear understanding of new testing and modelling methods that will improve the prediction and monitoring of structural integrity of advanced manufactured components. Join to hear case study insights from engineers who are adopting innovative advanced material and manufacturing technologies and modelling solutions to reduce risk and obtaining more reliable assets, including
- Nuclear AMRC
- Rolls Royce
- Coventry University
- Health and Safety Executive
- Wood Plc
- TWI
- Frazer Nash.
This seminar will seek to address the topic in a holistic manner which is not covered elsewhere, enabling attendees to improve reliability while reducing cost and eliminating waste.
To find out more and book your place, please visit www.imeche.org/structuralintegrity.