Single-piece airworthiness conformity verification method for additive manufacturing part of civil aircraft

Abstract

The invention discloses a civil aircraft additive manufacturing part single-piece airworthiness conformity verification method, which comprises the following steps: determining a damage mode of a part and designed and applicable airworthiness clause requirements, and establishing a verification scheme; carrying out test piece verification operation in turn; determining a new manufacturing scheme of the parts; verifying the manufactured part test piece according to the verification scheme; if the first preset condition is not met, the next round of test piece verification operation is carried out; if the first preset condition is met, using the new manufacturing scheme as an available manufacturing scheme for manufacturing the finished part; then, verifying the finished parts in turns; verifying the manufactured finished parts of the parts according to the verification scheme; if the second preset condition is not met, the test piece verification operation is carried out round by round to obtain a new available manufacturing scheme, and the next round of finished piece verification operation is carried out; and if a second preset condition is met, determining an airworthiness conformity verification result of the part.

Description

Technical Field

[0001] The present application relates to the field of aircraft airworthiness technology, and in particular to a method for verifying the airworthiness compliance of a single additively manufactured component of a civil aircraft. Background Art

[0002] As civil aircraft are characterized by high safety and high reliability, there are strict requirements for the design, manufacture and use of civil aircraft parts. Among them, normal, practical, aerobatic and commuter aircraft must meet the requirements of the "Airworthiness Regulations for Normal, Practical, Aerobatic and Commuter Aircraft" (such as 23.603 Material and Process Quality, 23.605 Manufacturing Method, 23.613 Material Strength Performance and Design Value, 23.305 Strength and Deformation, and 23.307 Proof of Structural Conformity in CCAR-23-R3); transport aircraft must meet the "Airworthiness Standards for Transport Aircraft" (such as 25.603 Material, 25.605 Manufacturing Method, 25.613 Material Strength Performance and Design Value, 25.305 Strength and Deformation, and 25.307 Proof of Structural Conformity in CCAR-25-R4).

[0003] In the prior art, the airworthiness compliance verification process for aircraft parts manufactured by traditional manufacturing processes (such as forging processes) must verify the material clauses (23.603, 25.603), the manufacturing method clauses (23.605, 25.605), the material strength properties and material design value clauses (23.613, 25.613), the strength and deformation clauses (23.305, 25.305) and the structural compliance proof clauses (23.307, 25.307) in order to achieve the airworthiness compliance verification of the parts, such as Figure 1 shown.

[0004] The above airworthiness compliance verification method for civil aircraft parts manufactured using traditional manufacturing processes is based on the following: (1) materials and manufacturing are two independent processes, and the material clauses (23.603, 25.603) and manufacturing method clauses (23.605, 25.605) can be verified separately; (2) the parts have acceptable material isotropy and structural uniformity, and the strength design of the parts can be carried out by establishing the material strength properties and the material design values ​​(23.613, 25.613), and the parts can be manufactured based on the design.

[0005] Nowadays, additive manufacturing technology is developing very rapidly. In the fields of aerospace and military aviation, additive manufacturing parts have been successfully applied to rockets, missiles and advanced fighter jets. Additive manufacturing technology is fast and efficient, and has great potential in manufacturing aircraft parts. Different from traditional manufacturing processes (such as forging processes), additive manufacturing uses a method of gradually accumulating materials to manufacture physical parts. The performance of parts manufactured by additive manufacturing processes is strongly affected by multiple factors such as the characteristics and quality stability of raw materials, the characteristics and precision stability of additive manufacturing equipment, the precision fluctuation of selected printing parameters and their matching, and has significant material anisotropy and structural inhomogeneity. Therefore: (1) The material and manufacturing of parts manufactured by additive manufacturing processes are an inseparable process, and the existing airworthiness compliance verification method of independently verifying materials and manufacturing methods is no longer applicable; (2) Parts prepared by additive manufacturing processes have significant material anisotropy and structural inhomogeneity. The material properties of each material point in the structure vary with the characteristics of the structure. The existing method of verifying the compliance of the structure by establishing the strength properties of the material and the design value of the material requires extremely large amounts of test data support, which is not economically feasible.

[0006] It can be seen that the airworthiness compliance verification method for parts manufactured by traditional manufacturing processes in the prior art is no longer applicable to verifying parts manufactured by additive manufacturing processes. The existing technology, through independent verification of raw material specifications and processes, blank material performance indicators and structural parts performance data, is difficult to solve the strong coupling effects of raw materials, printing equipment and printing parameters, as well as the effects of material anisotropy and structural non-uniformity of additively manufactured parts. It does not uniformly consider the failure mode of parts, the influence of multiple strong coupling factors and their effective verification methods, and requires a lot of test verification and analysis costs. Summary of the invention

[0007] The present invention provides a method for verifying the airworthiness compliance of a single additively manufactured component of a civil aircraft, so as to solve the technical problem of how to verify the airworthiness compliance of an additively manufactured component.

[0008] To solve the above technical problems, the embodiments of this specification provide the following technical solutions:

[0009] The embodiment of this specification provides a method for verifying the airworthiness compliance of a single part of an additively manufactured civil aircraft component, the method comprising:

[0010] Determine the failure mode and design of the parts based on the reference information of civil aircraft, and establish the corresponding verification plan for the parts based on the failure mode and design and the applicable airworthiness requirements;

[0011] The test piece verification operation is performed in rounds, and each round of the test piece verification operation includes: determining a new manufacturing scheme for the component according to the verification scheme; verifying the component test piece manufactured by the new manufacturing scheme according to the verification scheme; if the verification result does not meet the first preset condition, the next round of test piece verification operation is performed; if the verification result meets the first preset condition, the new manufacturing scheme is used as an available manufacturing scheme for manufacturing component finished products; by identifying one of the available manufacturing schemes, coupling the verification material and manufacturing method clauses; wherein, the component is a component to be manufactured by an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes the verification of materials and / or performance and performance stability;

[0012] The finished product verification operation is performed in rounds, and each round of finished product verification operation includes: verifying the finished component parts manufactured by the latest available manufacturing plan according to the verification plan; if the verification result does not meet the second preset condition, the test piece verification operation is performed again in rounds to obtain a new available manufacturing plan, and the next round of finished product verification operation is performed; if the verification result meets the second preset condition, the airworthiness compliance verification result of the component is determined, and the finished component part is identified as a qualified additively manufactured component; by identifying a qualified additively manufactured component, the proof clauses of strength, deformation and structural compliance are verified; wherein, the verification of the finished component parts includes the verification of product quality, strength, deformation and structural compliance.

[0013] Optionally, the verification scheme includes:

[0014] The component types, structures, loads, materials, geometric dimensions, new manufacturing solutions, verification methods and acceptance criteria used for verification are determined based on the described failure mode and the design and applicable airworthiness requirements.

[0015] Optionally, the verification scheme includes:

[0016] Verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing raw materials; the additive manufacturing raw materials are used to manufacture the component test pieces and finished parts.

[0017] Optionally, the verification scheme includes:

[0018] Verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing equipment; the additive manufacturing equipment is used to manufacture the component test pieces and finished parts.

[0019] Optionally, the verification scheme includes the first preset condition and the second preset condition:

[0020] The first preset condition is a verification method and acceptance criteria for indicating the material and / or performance of the component test piece and the performance stability;

[0021] The second preset condition is a verification method and acceptance criteria for indicating the product quality, strength, deformation and structural compliance of the component finished part.

[0022] Optionally, the new manufacturing solution includes an additive manufacturing solution, which includes selecting an additive manufacturing raw material, a set of additive manufacturing equipment, and a set of solidified additive manufacturing process parameters, and defining it as an additive manufacturing system.

[0023] Optional verification of finished component parts includes:

[0024] Conduct verification tests on finished parts of full-size parts under actual service loads, including non-destructive testing, mechanical and physical property testing and / or functional testing.

[0025] Optionally, an available manufacturing solution for manufacturing a finished component whose verification result meets the second preset condition is a target manufacturing solution for manufacturing the component.

[0026] Optionally, the method further includes:

[0027] For any two parts with the same failure mode, after determining the available manufacturing scheme for one of the parts, the available manufacturing scheme is used to perform a supplementary test piece verification operation on the other part to determine whether the available manufacturing scheme is the available manufacturing scheme for the other part;

[0028] For any two parts with exactly the same failure modes, after determining the available manufacturing solution for one of the parts, the available manufacturing solution is used to perform a finished product verification operation on the other part to determine whether the available manufacturing solution is the target manufacturing solution for the other part.

[0029] Optionally, for any round of test piece verification operation, a new manufacturing solution obtained from this round of test piece verification operation is different from the manufacturing solution obtained before this round of test piece verification operation.

[0030] At least one of the above technical solutions adopted in the embodiments of this specification can achieve the following beneficial effects:

[0031] A verification plan is established based on the failure mode and design of components and applicable airworthiness requirements. The component test pieces manufactured using additive manufacturing technology are verified through the verification plan to obtain a usable manufacturing plan that meets the requirements and can couple the verification of material and manufacturing method clauses. This allows the failure mode and design of components manufactured using additive manufacturing technology to be associated with the additive manufacturing technology that couples the verification of material and manufacturing method clauses, thereby achieving the effect of simultaneously verifying material and manufacturing method clauses.

[0032] Since the type of test pieces and the number of samples required for verification are determined by the failure mode, design and applicable airworthiness requirements of the components, verification of unnecessary types and numbers of test pieces is avoided, verification efficiency is improved and verification costs are reduced.

[0033] By conducting full-scale verification tests on finished parts manufactured using available manufacturing solutions under actual service loads, it is possible to directly verify the strength, deformation and structural compliance proof clauses without verifying the material's strength properties and material design value clauses, which can greatly save the R&D costs of establishing the material's strength properties and material design values.

[0034] It can be seen that the technical solutions adopted in the embodiments of this specification can improve the speed and efficiency of the airworthiness compliance verification of additively manufactured parts of civil aircraft and reduce the verification cost. It is applicable to the airworthiness compliance verification of civil aircraft parts and helicopters, military aircraft, aircraft engines and other aviation parts manufactured using additive manufacturing technology, including but not limited to, and can achieve the effect of application verification of additively manufactured parts in civil aircraft, helicopters, military aircraft and aircraft engines quickly, efficiently and at low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of this specification or the prior art, the drawings required for use in the embodiments of this specification or the prior art description are briefly described below. Obviously, the following only describes the drawings required for use in some embodiments of this application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor.

[0036] Figure 1 It is a flow chart of the airworthiness compliance verification of aircraft parts in the prior art.

[0037] Figure 2 It is a flow chart of a method for verifying the airworthiness compliance of a single additively manufactured component of a civil aircraft in an embodiment of this specification.

[0038] Figure 3It is a schematic diagram of the airworthiness compliance verification process of a single additively manufactured component of a civil aircraft in an embodiment of this specification.

[0039] Figure 4 It is a schematic diagram of the architecture of the verification solution in the embodiment of this specification.

[0040] Figure 5 It is a schematic diagram of the architecture of the additive manufacturing system in the embodiment of this specification. DETAILED DESCRIPTION

[0041] In order to enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of this specification will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments involved in the specific implementation methods are only part of the embodiments of this application, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments in the specific implementation methods without making creative work should belong to the scope of protection of this application.

[0042] The embodiments of this specification provide a method for verifying the airworthiness compliance of a single piece of additively manufactured parts for civil aircraft. The execution subject of the embodiment includes, but is not limited to, any material, part, component, airborne equipment or software used in civil aircraft or intended to be used and installed on civil aircraft, that is, the execution subject can be diverse and can be set, used or changed as needed. In addition, a third party may assist the execution subject in executing the embodiment. For example, the main manufacturer or supplier may execute the verification plan and / or new manufacturing plan in the embodiment, thereby assisting the authority and the reviewer in executing the method for verifying the airworthiness compliance of a single piece of additively manufactured parts for civil aircraft in the embodiment.

[0043] like Figure 2 and Figure 3 As shown, the embodiment provides a method for verifying the airworthiness compliance of a single part of an additively manufactured civil aircraft component, including:

[0044] S101: Determine the failure mode and design of the parts based on the reference information of the civil aircraft, and establish a verification plan corresponding to the parts based on the failure mode and design and applicable airworthiness requirements;

[0045] In an embodiment, the failure mode and design of a component can be determined based on the reference information of a civil aircraft. The content of the reference information is not limited, as long as it is helpful in determining the failure mode and design of the component. For example, the reference information of a civil aircraft includes but is not limited to the working condition and load condition of the aircraft, the function, characteristics and design requirements of the component, etc.

[0046] The component may be a specific or particular component, i.e. a single component having a component number. The component may be a component to be manufactured using an additive manufacturing process.

[0047] The failure modes of the parts include but are not limited to the failure modes caused by static loads, and the specific failure modes of the parts can be further determined, including but not limited to: tensile failure, compression failure, shear failure, instability failure and hole extrusion failure. For different parts, the determined failure modes may be different, and the embodiments are not limited. The parts described in the embodiments include but are not limited to static strength driven additive manufacturing parts, that is, additive manufacturing parts that mainly bear static loads, do not bear or only bear negligible fatigue and damage tolerance loads, and whose damage will not affect the safety of civil aircraft.

[0048] In the embodiment, a verification scheme corresponding to the component can be established according to the failure mode of the component, the design, and the applicable airworthiness requirements. The "verification scheme" here can be a set of verification indicators and methods of verification methods and acceptance criteria, and each component can have its corresponding verification scheme. When establishing a verification scheme, in addition to the failure mode of the component, the design, and the applicable airworthiness requirements, the function, characteristics, or other reference factors of the component can also be referred to, and the embodiment is not limited.

[0049] For any civil aircraft component, the corresponding verification plan may include the following contents:

[0050] The verification plan may include the type, structure, load, material, geometric dimensions, new manufacturing plan, verification method and acceptance criteria of the parts used for verification, determined according to the failure mode and design and applicable airworthiness requirements. The specific failure mode of the parts includes but is not limited to the failure mode caused by static load.

[0051] The verification scheme may include verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing raw materials. The additive manufacturing raw materials are used to manufacture the component test pieces and finished parts. Specifically, the performance and performance stability indicators of the additive manufacturing raw materials include but are not limited to: the chemical composition of the metal powder or wire raw materials, the particle size distribution, fluidity, tap density, bulk density of the powder, and the external dimensions of the wire and its allowable deviation, appearance quality, and key control parameters of the production process.

[0052] The verification scheme may include verification methods and acceptance criteria for demonstrating the performance and performance stability of the additive manufacturing equipment, wherein the additive manufacturing equipment is used to manufacture the component test piece and the finished product. Specifically, the performance and performance stability indicators of the additive manufacturing equipment include, but are not limited to: molding size, molding accuracy, accuracy and stability indicators of key components, accuracy and stability indicators of control software, and accuracy and stability indicators of key process parameters.

[0053] The verification plan may include verification methods and acceptance criteria for demonstrating the material and / or performance and performance stability of the component test piece, i.e. the first precondition. The specific test piece type, geometric dimensions, sampling quantity, test method, material and / or performance and performance stability index, and acceptance criteria of the component used for verification shall be determined by the failure mode and design of the component and the applicable airworthiness clause requirements;

[0054] The verification plan may include verification methods and acceptance criteria for demonstrating the product quality, strength, deformation and structural compliance of the finished component, i.e. the second precondition. The specific finished component type and structure, load, geometric dimensions, sampling quantity, test method, quality requirements, performance and / or functional indicators, and acceptance criteria of the component used for verification are determined by the failure mode and design of the component and the applicable airworthiness clause requirements.

[0055] The verification scheme may also include other contents, which are not limited in the embodiments. The verification schemes corresponding to the same type of components may be the same or different, which are not limited in the embodiments.

[0056] S103: Perform test piece verification operations in rounds, and each round of test piece verification operations includes: determining a new manufacturing scheme for the component according to the verification scheme; verifying the component test piece manufactured by the new manufacturing scheme according to the verification scheme; if the verification result does not meet the first preset condition, performing the next round of test piece verification operations; if the verification result meets the first preset condition, using the new manufacturing scheme as an available manufacturing scheme for manufacturing component finished products; by identifying one of the available manufacturing schemes, coupling the verification of material and manufacturing method clauses; wherein, the component is a component to be manufactured by an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes the verification of materials and / or performance and performance stability;

[0057] In an embodiment, the test piece verification operation may be performed in rounds, and each round of the test piece verification operation may include the following contents:

[0058] For any component, a new manufacturing plan (hereinafter referred to as the "new manufacturing plan") for the component is determined based on the verification plan corresponding to the component. The manufacturing plan determined in the first round of test piece verification operation also belongs to the new manufacturing plan. Among them, the new manufacturing plan includes an additive manufacturing plan (the additive manufacturing plan is used to manufacture the test piece of the component). Specifically, the contents included in the verification plan have been explained above. These contents cover the verification methods and acceptance criteria related to additive manufacturing raw materials and additive manufacturing equipment. Therefore, an additive manufacturing plan can be determined based on the verification plan. The additive manufacturing plan includes selecting an additive manufacturing raw material, a set of additive manufacturing equipment, and a set of solidified additive manufacturing process parameters, and defining them as an additive manufacturing system, which all meet the requirements of the verification plan.

[0059] The component test pieces manufactured by the new manufacturing plan (i.e., the test pieces corresponding to the selected type, geometric dimensions, sampling quantity, test method, material and / or performance, performance stability index, and acceptance criteria of the component in the verification plan) are verified according to the verification plan corresponding to the component to obtain the verification results. Among them, according to the requirements of the verification plan, various verifications including but not limited to material and / or performance and performance stability verification can be carried out on the component test pieces to verify the materials and / or performance and performance stability of the component test pieces. Specifically, the component test pieces can be subjected to tests including but not limited to material characterization, mechanical and physical performance testing to obtain the required material characterization, mechanical and physical performance test results (which belong to verification results).

[0060] If the verification result (i.e., the verification result of the test piece) does not meet the first preset condition (the first preset condition may be included in the verification scheme, for example, the first preset condition may be a preset verification method and acceptance criteria for indicating the material and / or performance and performance stability of the component test piece, including the acceptance standard), then continue to perform the next round of test piece verification operation according to the above steps. That is, determine the new manufacturing scheme of the component again; verify the component test piece manufactured by the new manufacturing scheme according to the verification scheme, and determine whether the verification result meets the first preset condition.

[0061] If the verification result (i.e., the verification result of the test piece) meets the first preset condition (i.e., the material and / or performance and performance stability of the component test piece meet the requirements of the verification plan), the new manufacturing plan in the current round of test piece verification operation is used as an available manufacturing plan for manufacturing the component finished product. After determining the available manufacturing plan, the next round of test piece verification operation can be temporarily stopped.

[0062] According to the above content, through one or more rounds of test piece verification operations, an available manufacturing solution can be obtained after a certain round of test piece verification operations, and the available manufacturing solution can be used as a qualified manufacturing solution capable of manufacturing the finished component. Among them, the available manufacturing solution includes an additive manufacturing solution, that is, an additive manufacturing system determined by selecting an additive manufacturing raw material, a set of additive manufacturing equipment, and a set of solidified additive manufacturing process parameters, and the additive manufacturing system can be used as a qualified additive manufacturing system capable of manufacturing the finished component.

[0063] Since the verification results are obtained according to the verification plan, and the materials and / or performance and performance stability obtained are in compliance with the verification plan requirements, and an available manufacturing plan including an additive manufacturing system (the additive manufacturing system belongs to the manufacturing method) is available, it is possible to couple the material and manufacturing method clauses (these clauses can be included in the verification plan, that is, the applicable airworthiness clause requirements) by identifying an available manufacturing plan.

[0064] S105: Perform finished part verification operations in rounds, and each round of finished part verification operations includes: verifying the finished parts of the components manufactured by the latest available manufacturing solution according to the verification solution; if the verification result does not meet the second preset condition, then perform the test piece verification operation in rounds again to obtain a new available manufacturing solution, and perform the next round of finished part verification operations; if the verification result meets the second preset condition, determine the airworthiness compliance verification result of the component, and identify the finished component as a qualified additively manufactured component; by identifying a qualified additively manufactured component, verify the proof clauses of strength, deformation and structural compliance; wherein, the verification of the finished component includes the verification of product quality, strength, deformation and structural compliance.

[0065] In an embodiment, the finished product verification operation may be performed in rounds, and each round of the finished product verification operation may include the following contents:

[0066] Following the above-mentioned component, the finished component (the "finished component" here generally refers to the full-size sample of the component, that is, the finished component corresponding to the selected type and structure, load, geometric size, sampling quantity, test method, quality requirements, performance and / or functional indicators, and acceptance criteria of the component in the verification plan) is verified according to the verification plan to obtain the verification results. Among them, according to the requirements of the verification plan, the finished component can be verified including but not limited to product quality, strength and deformation, and structural compliance. Specifically, the verification of the finished component can include: conducting a verification test of the full-size component under the actual service load on the finished component, and the verification test includes but is not limited to non-destructive testing, mechanical and physical performance testing and / or functional testing to obtain the required non-destructive testing, mechanical and physical performance testing and / or functional testing results (which belong to the verification results) of the component.

[0067] If the verification result (i.e., the verification result of the finished part) does not meet the second preset condition (the second preset condition may be included in the verification plan, for example, the second preset condition may be a preset verification method and acceptance criteria, including acceptance standards, used to indicate the product quality, strength and deformation, and structural compliance of the finished part), the above-mentioned test piece verification operation is performed again in rounds to obtain a new available manufacturing plan and perform the next round of finished part verification operation.

[0068] If the verification result (i.e., the verification result of the finished part) meets the second preset condition (i.e., the product quality, strength, deformation and structural compliance of the component finished part meet the requirements of the verification plan), it can be determined that the component finished part that meets the second preset condition is a qualified additively manufactured component finished part, and the airworthiness compliance verification result of the component finished part can be determined.

[0069] Since the verification result is obtained according to the verification plan, and what is obtained is a qualified additive manufacturing component finished product whose product quality, strength, deformation and structural compliance meet the requirements of the verification plan, the above content adopts the latest available manufacturing plan, which has the effect of verifying the material and manufacturing method clauses at the same time. Therefore, by identifying a qualified additive manufacturing component, the proof clauses of strength, deformation and structural compliance can be directly verified (these clauses can be included in the verification plan, that is, the applicable airworthiness clause requirements) without verifying the strength performance and design value clauses of the material. Therefore, the airworthiness compliance verification results of the corresponding additive manufacturing components can be determined more quickly and efficiently based on the verification results (the airworthiness compliance verification results include but are not limited to the verification results of the material and manufacturing method clauses of the additive manufacturing component, and the verification results of the strength, deformation and structural compliance clauses).

[0070] According to the above content, through one or more rounds of finished product verification operations, a finished component that has passed the airworthiness compliance verification can be obtained after a certain round of finished product verification operations. In addition, the available manufacturing scheme for manufacturing the "finished component whose verification result meets the second preset condition" is determined as the target manufacturing scheme for manufacturing the component.

[0071] In the above content, for any round of test piece verification operation, the new manufacturing plan obtained by this round of test piece verification operation is different from the manufacturing plan obtained before this round of test piece verification operation, that is, the manufacturing plan obtained in each round of test piece verification operation is new and does not repeat the previous manufacturing plan.

[0072] In an embodiment, for any two parts with partially identical failure modes, after determining the available manufacturing scheme for one of the parts, the available manufacturing scheme can be used to perform a supplementary test piece verification operation on the other part to determine whether the available manufacturing scheme is the available manufacturing scheme for the other part; for any two parts with completely identical failure modes, after determining the available manufacturing scheme for one of the parts, the available manufacturing scheme can be used to perform a finished product verification operation on the other part to determine whether the available manufacturing scheme is the target manufacturing scheme for the other part.

[0073] For example, assuming that the failure mode of a specific component A to be manufactured using the same additive manufacturing solution (including a selected additive manufacturing raw material, a set of additive manufacturing equipment, and a set of solidified additive manufacturing process parameters) is tensile failure, the failure mode of another specific component B is tensile failure (and the same as the tensile failure mode of component A) and compression failure (partially the same as the failure mode of component A), and the failure mode of the third specific component C is also tensile failure and compression failure (and exactly the same as the failure mode of component B). Components A, B, and C have different part numbers. Then, the verification solution established for component A can be partially applicable to component B; the verification solution established for component B can be partially applicable to component C.

[0074] Through one or more rounds of test piece verification operations, a usable manufacturing scheme for manufacturing component A is obtained. This usable manufacturing scheme can be used to manufacture the finished product of component A, but it is not necessarily suitable for manufacturing the finished product of component B (because the failure modes of components A and B are partially the same). Therefore, on the basis of obtaining the usable manufacturing scheme for component A, the manufacturing and test piece verification operations for the selected type of compression test piece of component B can be supplemented. That is, a round of supplementary test piece verification operations for the selected type of compression test piece of component B is performed. In the test piece verification operation, the usable manufacturing scheme is used as a new manufacturing scheme for manufacturing component B, and the manufactured selected type of compression test piece of component B is verified. According to whether the verification result meets the first preset condition (the content of the first preset condition for different types of components may be different), it is determined whether the usable manufacturing scheme is the usable manufacturing scheme for component B.

[0075] If the test result meets the first preset condition, the available manufacturing solution is an available manufacturing solution for component B, and the available manufacturing solution can also be used to manufacture the finished product of component B. The available manufacturing solution is qualified for the test piece verification operation of component A and component B. At the same time, since the failure modes of component B and component C are exactly the same, the available manufacturing solution can also be used as an available manufacturing solution for component C, and the available manufacturing solution can also be used to manufacture the finished product of component C. The available manufacturing solution is qualified for the test piece verification operation of component B and component C.

[0076] As can be seen from the above, any two parts with the same or identical failure modes may use the same available manufacturing solution. Any two parts with the same or identical failure modes (i.e., individual parts with component part numbers) may be independently subjected to finished product part verification operations to determine whether the same available manufacturing solution is the target manufacturing solution for these different individual parts.

[0077] The following is a further explanation of the airworthiness compliance verification method for a single additively manufactured component of a civil aircraft by taking an example:

[0078] Taking the additive manufacturing parts of civil aircraft as aircraft parts, more specifically the titanium alloy gooseneck hinge parts of civil aircraft by laser selective melting as an example, according to the working conditions and load conditions of civil aircraft, the functions, characteristics and design requirements of gooseneck hinge parts, the failure mode of the aircraft parts (also refers to a specific aircraft part, that is, a single part with a part number) to be manufactured by additive manufacturing process (such as laser selective melting) is determined to be the failure mode caused by static load, and the "failure mode of parts and design, applicable airworthiness requirements" are determined. 1 In this example, the aircraft parts are titanium alloy gooseneck hinge parts to be manufactured by laser selective melting process, and its failure mode is the failure mode caused by static load, and one of the specific failure modes of the titanium alloy gooseneck hinge parts is determined to be tensile failure.

[0079] According to the above failure modes and design and applicable airworthiness requirements, a verification scheme corresponding to titanium alloy gooseneck hinge parts can be established, such as Figure 4 shown.

[0080] The verification plan may include the failure mode and design of the titanium alloy gooseneck hinge parts to be manufactured by the laser selective melting process, applicable airworthiness requirements 1, and the type and structure, load, material, geometric dimensions, new manufacturing plan, verification method and acceptance criteria of the gooseneck hinge parts used for verification determined according to the above failure mode and design and applicable airworthiness requirements.

[0081] The verification scheme may include "verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing raw materials"2. In this example, the verification methods and acceptance criteria (including but not limited to verification indicators and acceptance standards) for demonstrating the performance and performance stability of raw materials used for laser selective melting to manufacture titanium alloy gooseneck hinge parts. Among them, the raw material is titanium alloy powder (such as Ti-6Al-4V), and the verification indicators of raw material performance and performance stability include but are not limited to the chemical composition of titanium alloy powder, particle size distribution of powder, fluidity, tap density, bulk density, and key control parameters of the production process.

[0082] The verification plan may include "verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing equipment"3. In this example, it is to demonstrate the verification method and acceptance criteria (including but not limited to verification indicators and acceptance standards) for the performance and performance stability of additive manufacturing equipment used for laser selective melting to manufacture titanium alloy gooseneck hinge parts. Among them, the additive manufacturing equipment is a laser selective melting printing device (such as EOS M280), and the verification indicators of the performance and performance stability of the additive manufacturing equipment include but are not limited to the forming size, forming accuracy, accuracy and stability indicators of key components of the laser selective melting equipment, accuracy and stability indicators of the control software, and accuracy and stability indicators of key process parameters.

[0083] The verification scheme may include “the verification method and acceptance criteria for demonstrating the material and / or performance and performance stability of the component test piece, i.e., the first preset condition; and the verification method and acceptance criteria for demonstrating the product quality, strength and deformation and structural compliance of the component finished product, i.e., the second preset condition”4. In this example, it is the verification method and acceptance criteria for indicating the material and / or performance and performance stability of the component test piece (such as the tensile test piece) manufactured by the selective laser melting process, that is, the first preset condition; wherein, the type of the component test piece used for verification is the tensile test piece, and the geometric dimensions, sampling quantity, test method, material and / or performance and performance stability index, and acceptance criteria of the tensile test piece are determined by the failure mode and design of the titanium alloy gooseneck hinge part, and the applicable airworthiness requirements; the verification method and acceptance criteria for indicating the product quality, strength and deformation and structural compliance of the finished component (such as the full-size sample of the titanium alloy gooseneck hinge part) manufactured by the selective laser melting process, that is, the second preset condition; wherein, the type and structure, load, geometric dimensions, sampling quantity, test method, quality requirements, performance and / or functional index, and acceptance criteria of the full-size sample of the titanium alloy gooseneck hinge part used for verification are determined by the failure mode and design of the titanium alloy gooseneck hinge part, and the applicable airworthiness requirements.

[0084] In a round of test piece verification operation, a new manufacturing plan for the component is determined according to the verification plan, and the new manufacturing plan includes an additive manufacturing plan, and the additive manufacturing plan includes selecting an additive manufacturing raw material 5, a set of additive manufacturing equipment 6, and a set of solidified additive manufacturing process parameters 7. These contents can be defined as an additive manufacturing system (belonging to the new manufacturing plan), such as Figure 5As shown. In this example, a new manufacturing scheme for titanium alloy gooseneck hinge parts is specifically determined, and the new manufacturing scheme includes an additive manufacturing scheme and a corresponding post-processing scheme (such as powder cleaning, support removal, heat treatment, surface treatment), etc. The additive manufacturing scheme includes selecting a titanium alloy powder raw material (such as Ti-6Al-4V powder), a set of additive manufacturing equipment (such as EOS M280 equipment) and a set of solidified laser selective melting forming process parameters (such as a set of solidified process parameters, including but not limited to laser power, scanning speed, scanning trajectory, printing layer thickness, etc.), and is defined as an additive manufacturing system. Through the obtained additive manufacturing system, the above-selected type of test piece, that is, the tensile test piece, can be manufactured to indicate the material and / or performance and performance stability of the component test piece manufactured by the laser selective melting process. Of course, it is also possible to select a suitable heat treatment process to heat treat the tensile test piece, and select a suitable machining process to machine the tensile test piece to achieve the required surface quality and dimensional accuracy requirements of the tensile test piece, which is used to verify the material and / or performance and performance stability indicators of the tensile test piece manufactured by the laser selective melting process.

[0085] According to the verification plan, various verifications including but not limited to material and / or performance and performance stability verification are carried out on the component test pieces. Specifically, the component test pieces can be subjected to tests including but not limited to material characterization, mechanical and physical property testing to obtain the required material characterization, mechanical and physical property testing results (which belong to verification results). In this example, a tensile test is carried out on the tensile test piece manufactured by the laser selective melting process to obtain the required material tensile test results (such as tensile strength, yield strength, elongation, etc., which belong to verification results). Of course, the chemical composition, microstructure, etc. of the workpiece can also be inspected and the inspection results can be obtained (which belong to verification results)

[0086] If the verification result (i.e., the verification result of the test piece) does not meet the expected acceptance criteria (the expected acceptance criteria belong to the first preset condition), it means that the new manufacturing scheme of the component determined above cannot be used as an available manufacturing scheme for manufacturing the finished component, and it is necessary to continue to perform the next round of test piece verification operations according to the above steps, that is, to re-determine the new manufacturing scheme of the component (such as re-selecting a raw material, a set of additive manufacturing equipment, and a set of solidified additive manufacturing process parameters, i.e., an additive manufacturing system), and to conduct a verification test on the test piece manufactured by the re-determined new manufacturing scheme, and obtain the verification results. In this example, if the test results obtained by the tensile test piece for the tensile test piece do not meet the expected acceptance criteria (for example, the acceptance criteria for performance indicators such as tensile strength, yield strength, and elongation used to indicate the performance and performance stability of the tensile test piece manufactured by the laser selective melting process), the new manufacturing scheme of the titanium alloy gooseneck hinge determined above cannot be used as an available manufacturing scheme for manufacturing the finished titanium alloy gooseneck hinge, and the next round of test piece verification operations is required.

[0087] If the test results (i.e., the verification results of the test piece) meet the expected acceptance criteria (the expected acceptance criteria belong to the first preset condition), it means that the new manufacturing scheme of the component determined by the current round of test piece verification operation can be used as an available manufacturing scheme for manufacturing the finished component. In this example, if the test results obtained by conducting a tensile test on the tensile test piece meet the expected acceptance criteria (for example, it can be the acceptance criteria for performance indicators such as tensile strength, yield strength, and elongation that indicate the performance and performance stability of the tensile test piece manufactured using the laser selective melting process), the new manufacturing scheme of the titanium alloy gooseneck hinge determined by the current round of test piece verification operation will be used as an available manufacturing scheme for manufacturing the finished titanium alloy gooseneck hinge (i.e., the full-size sample of the titanium alloy gooseneck hinge part). After determining the available manufacturing scheme, the next round of test piece verification operation can be temporarily stopped.

[0088] Through the above-mentioned one or more rounds of test piece verification operations, it is ensured that the available manufacturing scheme obtained can be used as a qualified manufacturing scheme with the ability to manufacture the finished parts of the component. In this example, the available manufacturing scheme obtained through one or more rounds of tensile test piece verification operations is a material and / or performance and performance stability that meets the requirements of the titanium alloy gooseneck hinge part verification scheme, and the available manufacturing scheme has the ability to manufacture full-size samples of titanium alloy gooseneck hinge parts. By identifying an available manufacturing scheme, it is possible to couple the verification of material and manufacturing method clauses (such as 23.603, 25.603, 23.605, 25.605).

[0089] Through the latest available manufacturing solutions (including additive manufacturing solutions), corresponding finished parts can be manufactured to verify the product quality, strength, deformation, and structural compliance of the finished parts prepared by the additive manufacturing process. In this example, the corresponding full-size sample of the titanium alloy gooseneck hinge part is manufactured through the available manufacturing solution determined above, and at the same time, a suitable heat treatment process is selected to heat treat the full-size sample of the titanium alloy gooseneck hinge part, and a suitable machining process is selected to machine the full-size sample of the titanium alloy gooseneck hinge part to achieve the required surface quality and dimensional accuracy requirements of the finished titanium alloy gooseneck hinge part, which is used to verify the product quality, strength, deformation, and structural compliance of the finished titanium alloy gooseneck hinge part prepared by the laser selective melting process.

[0090] In a round of finished parts verification operation, according to the verification plan, the finished parts are subjected to verification tests of full-size parts under the actual service load, and the verification tests include but are not limited to non-destructive testing, mechanical and physical performance testing and / or functional testing, so as to obtain the required non-destructive testing, mechanical and physical performance testing and / or functional testing results (which belong to the verification results) of the finished parts. In this example, the finished titanium alloy gooseneck hinge parts can be subjected to verification tests of full-size parts under the actual service load, and the verification tests include but are not limited to non-destructive testing (such as visual inspection, fluorescent penetration, X-ray inspection), mechanical and physical performance testing and / or functional testing (such as tensile testing and functional testing under actual load conditions), so as to obtain the required non-destructive testing, mechanical and physical performance testing and / or functional testing results (which belong to the verification results) of the finished titanium alloy gooseneck hinge parts.

[0091] If the test results (i.e., the verification results of the finished parts) do not meet the expected acceptance criteria (the expected acceptance criteria belong to the second preset condition), the available manufacturing solution obtained above will still be deemed unusable, and it is necessary to continue to perform the above-mentioned test piece verification operation in rounds to obtain a new available manufacturing solution again, and continue to perform the next round of finished part verification operation. In this example, if the test results of the verification test of the titanium alloy gooseneck hinge parts under the actual service load do not meet the expected acceptance criteria (including but not limited to the quality requirements, performance and / or functional indicators used to indicate the product quality, strength and deformation and structural compliance of the titanium alloy gooseneck hinge parts manufactured by the laser selective melting process), the manufactured titanium alloy gooseneck hinge parts are identified as unqualified additive manufacturing parts, and the available manufacturing solution obtained above is still deemed unusable, and it is necessary to continue to perform the test piece verification operation in rounds and obtain a new available manufacturing solution again.

[0092] If the test results (i.e., the verification results of the finished parts) meet the expected acceptance criteria (the expected acceptance criteria belong to the second preset conditions), it can be determined that the finished parts that meet the second preset conditions are qualified additive manufacturing finished parts, and the airworthiness compliance verification results of the finished parts can be determined to have passed the verification. In addition, the available manufacturing scheme used to manufacture the "finished parts whose verification results meet the second preset conditions" is determined as the target manufacturing scheme for manufacturing the said parts. In this example, if the test results of the verification test of the titanium alloy gooseneck hinge parts of the finished parts of the full-size parts under the actual service load meet the expected acceptance criteria (including but not limited to the quality requirements, performance and / or functional indicators for indicating the product quality, strength and deformation and structural compliance of the titanium alloy gooseneck hinge parts manufactured by the laser selective melting process), the manufactured titanium alloy gooseneck hinge parts are identified as qualified additive manufacturing parts, and the available manufacturing scheme obtained above is determined as the target manufacturing scheme for manufacturing titanium alloy gooseneck hinge parts.

[0093] It can be seen from this example that the technical solution of the embodiment obtains a qualified additive manufacturing component whose product quality, strength, deformation and structural compliance meet the requirements of the verification scheme. The above content adopts the latest available manufacturing scheme, which has the effect of verifying the material and manufacturing method clauses at the same time. Therefore, by identifying a qualified additive manufacturing component, the proof clauses of strength, deformation and structural compliance can be directly verified without verifying the strength performance and design value clauses of the material. For example, in this example, by identifying a qualified titanium alloy gooseneck hinge component manufactured by laser selective melting forming process, the proof clauses of strength, deformation and structural compliance of the titanium alloy gooseneck hinge component (such as 23.305, 25.305, 23.307, 25.307) can be directly verified without verifying the strength performance and design value clauses of the material (such as 23.613, 25.613). In addition, this example reflects the application of the embodiment in the trial production and airworthiness compliance verification of additive manufacturing components for civil aircraft using titanium alloy laser selective melting process, and reflects the feasibility of the technical solution of the embodiment.

[0094] The embodiments can achieve the following beneficial effects:

[0095] The failure modes and designs of parts manufactured using additive manufacturing processes are associated with available manufacturing solutions (including additive manufacturing solutions) that couple and verify material and manufacturing method terms, solving the problem that existing technologies cannot simultaneously verify material and manufacturing method terms.

[0096] A verification plan is established based on the failure mode and design of parts and components and applicable airworthiness requirements. The verification plan is used to verify the test pieces and finished parts manufactured using additive manufacturing technology, and a target manufacturing plan that meets the requirements and can couple the verification of material and manufacturing method clauses is obtained. This allows the failure mode and design of parts and components manufactured using additive manufacturing technology to be associated with the additive manufacturing technology that couples the verification of material and manufacturing method clauses. There is no need to separate the materials and manufacturing processes of parts and components, thus achieving the effect of simultaneously coupling the verification of material and manufacturing method clauses.

[0097] Since the type of test pieces and the number of samples required for verification are determined by the failure mode and design of the component and the applicable airworthiness requirements, unnecessary types and numbers of test pieces are avoided, verification efficiency is improved, and verification costs are reduced. The established verification scheme includes the failure mode and design of the component, applicable airworthiness requirements, and the type and structure, load, material, geometric dimensions, new manufacturing scheme, verification method and acceptance criteria of the component used for verification determined according to the failure mode and design and applicable airworthiness requirements, verification method and acceptance criteria for indicating the performance and performance stability of additive manufacturing raw materials, verification method and acceptance criteria for indicating the performance and performance stability of additive manufacturing equipment, and verification method and acceptance criteria for indicating the material and / or performance and performance stability of component test pieces (i.e., the first preset condition) and verification method and acceptance criteria for indicating the product quality, strength and deformation and structural compliance of component finished parts (i.e., the second preset condition), which ensures the feasibility and richness of verification of test piece verification operations and finished part verification operations.

[0098] During the test piece verification operation, a new manufacturing plan is used to manufacture test pieces of selected type, geometric dimensions, sampling quantity, test method, material and / or performance, performance stability index, and acceptance criteria determined by the failure mode and design of the parts and applicable airworthiness requirements, and various verification tests including but not limited to materials and / or performance and performance stability are carried out on the selected test pieces to obtain the required verification results including but not limited to material characterization, mechanical and physical properties test results, thereby ensuring that the available manufacturing plan that meets the requirements obtained according to the verification plan can be coupled to verify the material and manufacturing method clauses.

[0099] By conducting verification tests on finished parts manufactured using available manufacturing solutions under real service loads (including but not limited to non-destructive testing, mechanical and physical property testing and / or functional testing, and obtaining the required non-destructive testing, mechanical and physical property testing and / or functional testing results of finished parts), the proof clauses of strength, deformation and structural compliance can be directly verified without verifying the strength properties of the material and the design value clauses of the material.

[0100] In view of the strong coupling characteristics of raw materials, printing equipment and printing parameters in the additive manufacturing process of civil aircraft parts, as well as the material anisotropy and structural inhomogeneity of the formed parts, the embodiment first couples and verifies the material and manufacturing method clauses, and then directly verifies the strength and deformation and structural compliance clauses without verifying the material strength performance and design value clauses. It can be seen that the technical solution of the embodiment can greatly save the cost of establishing the material strength performance and design value.

[0101] It can be seen that the technical solutions adopted in the embodiments of this specification can improve the speed and efficiency of the airworthiness compliance verification of additively manufactured parts of civil aircraft and reduce the verification cost. It is applicable to the airworthiness compliance verification of civil aircraft parts and helicopters, military aircraft, aircraft engines and other aviation parts manufactured using additive manufacturing technology, including but not limited to, and can quickly, efficiently and at low cost achieve the effect of application verification of additively manufactured parts in civil aircraft, helicopters, military aircraft and aircraft engines.

[0102] The above is only an embodiment of this specification and is not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.

Claims

1. A method for verifying the airworthiness compliance of a single part of an additively manufactured civil aircraft component, characterized in that: The method comprises: Determine the failure mode and design of the parts based on the reference information of civil aircraft, and establish the corresponding verification plan for the parts based on the failure mode and design and the applicable airworthiness requirements; The test piece verification operation is performed in rounds, and each round of the test piece verification operation includes: determining a new manufacturing scheme for the component according to the verification scheme; verifying the component test piece manufactured by the new manufacturing scheme according to the verification scheme; if the verification result does not meet the first preset condition, the next round of test piece verification operation is performed; if the verification result meets the first preset condition, the new manufacturing scheme is used as an available manufacturing scheme for manufacturing component finished products; by identifying one of the available manufacturing schemes, coupling the verification material and manufacturing method clauses; wherein, the component is a component to be manufactured by an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes the verification of materials and / or performance and performance stability; The finished product verification operation is performed in rounds, and each round of finished product verification operation includes: verifying the finished component parts manufactured by the latest available manufacturing plan according to the verification plan; if the verification result does not meet the second preset condition, the test piece verification operation is performed again in rounds to obtain a new available manufacturing plan, and the next round of finished product verification operation is performed; if the verification result meets the second preset condition, the airworthiness compliance verification result of the component is determined, and the finished component part is identified as a qualified additively manufactured component; by identifying a qualified additively manufactured component, the proof clauses of strength, deformation and structural compliance are verified; wherein, the verification of the finished component parts includes the verification of product quality, strength, deformation and structural compliance.

2. The method according to claim 1, characterized in that The verification scheme includes: The component types, structures, loads, materials, geometric dimensions, new manufacturing solutions, verification methods and acceptance criteria used for verification are determined based on the described failure mode and the design and applicable airworthiness requirements.

3. The method according to claim 1, characterized in that The verification scheme includes: Verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing raw materials; the additive manufacturing raw materials are used to manufacture the component test pieces and finished parts.

4. The method according to claim 1, characterized in that The verification scheme includes: Verification methods and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing equipment; the additive manufacturing equipment is used to manufacture the component test pieces and finished parts.

5. The method according to claim 1, characterized in that The verification scheme includes the first preset condition and the second preset condition: The first preset condition is a verification method and acceptance criteria for indicating the material and / or performance of the component test piece and the performance stability; The second preset condition is a verification method and acceptance criteria for indicating the product quality, strength, deformation and structural compliance of the component finished part.

6. The method according to claim 1, characterized in that The new manufacturing scheme includes an additive manufacturing scheme, which includes selecting an additive manufacturing raw material, a set of additive manufacturing equipment and a set of solidified additive manufacturing process parameters, and defining it as an additive manufacturing system.

7. The method according to claim 1, characterized in that Verification of finished parts includes: Conduct verification tests on finished parts of full-size parts under actual service loads, including non-destructive testing, mechanical and physical property testing and / or functional testing.

8. The method according to claim 1, characterized in that The available manufacturing solution for manufacturing a component finished product whose verification result meets the second preset condition is the target manufacturing solution for manufacturing the component.

9. The method according to claim 1, characterized in that The method further comprises: For any two parts with the same failure mode, after determining the available manufacturing scheme for one of the parts, the available manufacturing scheme is used to perform a supplementary test piece verification operation on the other part to determine whether the available manufacturing scheme is the available manufacturing scheme for the other part; For any two parts with exactly the same failure modes, after determining the available manufacturing solution for one of the parts, the available manufacturing solution is used to perform a finished product verification operation on the other part to determine whether the available manufacturing solution is the target manufacturing solution for the other part.

10. The method according to any one of claims 1 to 9, characterized in that For any round of test piece verification operation, the new manufacturing plan obtained by the round of test piece verification operation is different from the manufacturing plan obtained before the round of test piece verification operation.

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