Civil aircraft additive manufacturing part single piece airworthiness compliance verification method

Abstract

The application discloses a kind of civil aircraft additive manufacturing parts single piece airworthiness compliance verification method, comprising: determining the failure mode of part and design, applicable airworthiness clause requirement, establish verification scheme;According to the verification scheme, the test piece of the part manufactured is verified;If the first preset condition is not reached, the next round of test piece verification operation is carried out;If the first preset condition is reached, the new manufacturing scheme is used as the available manufacturing scheme for manufacturing part finished piece;Then, according to the verification scheme, the finished piece of the part manufactured is verified;If the second preset condition is not reached, the test piece verification operation is carried out again, a new available manufacturing scheme is obtained, and the next round of finished piece verification operation is carried out;If the second preset condition is reached, the airworthiness compliance verification result of part is determined.

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] Due to the high safety and reliability characteristics of civil aircraft, strict requirements are imposed on the design, manufacture, and use of civil aircraft components. Normal, utility, aerobatic, and commuter category aircraft must meet the requirements of the "Airworthiness Regulations for Normal, Utility, Acrobatic, and Commuter Category Airplanes" (e.g., CCAR-23-R3, 23.603 Materials and Workmanship, 23.605 Manufacturing Methods, 23.613 Material Strength Properties and Design Values, 23.305 Strength and Deformation, and 23.307 Demonstration of Structural Conformity). Transport category aircraft must meet the "Airworthiness Standards for Transport Category Airplanes" (e.g., CCAR-25-R4, 25.603 Materials, 25.605 Manufacturing Methods, 25.613 Material Strength Properties and Design Values, 25.305 Strength and Deformation, and 25.307 Demonstration of Structural Conformity).

[0003] In the existing technology, 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), manufacturing method clauses (23.605, 25.605), material strength properties and material design value clauses (23.613, 25.613), strength and deformation clauses (23.305, 25.305) and structural compliance proof clauses (23.307, 25.307) in sequence, so as to achieve the airworthiness compliance verification of parts, such as Figure 1 shown.

[0004] The above airworthiness conformity 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 strength properties of the materials and the design values ​​of the materials (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. Unlike traditional manufacturing processes (such as forging processes), additive manufacturing uses a method of gradually accumulating materials to manufacture solid 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. The existing airworthiness compliance verification method of independently verifying the material and manufacturing method clauses 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 and is not economically feasible.

[0006] Clearly, existing airworthiness compliance verification methods for parts manufactured using traditional manufacturing processes are no longer applicable to parts manufactured using additive manufacturing. Existing approaches, which rely on independent verification of raw material specifications and processes, blank material performance indicators, and structural component performance data, struggle to address the strong coupling effects of raw materials, printing equipment, and printing parameters, as well as the influence of material anisotropy and structural inhomogeneity in additively manufactured parts. They also fail to uniformly consider component failure modes, the impact of multiple strong coupling factors, and effective verification pathways, and require significant testing, 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 perform airworthiness compliance verification of additively manufactured components.

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

[0009] The present invention provides a method for verifying the airworthiness conformity of a single additively manufactured component of a civil aircraft. The method includes:

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

[0011] Performing test piece verification operations in rounds, each round of test piece verification operations including: 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 the component finished product; coupling verification of material and manufacturing method clauses by identifying one of the available manufacturing schemes; wherein, the component is a component to be manufactured using an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes verification of materials and / or performance and performance stability;

[0012] The finished part verification operation is performed in rounds, and each round of finished part verification operation includes: verifying the finished parts of the component 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 in rounds again to obtain a new available manufacturing plan, and the next round of finished part 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 part of the component is identified as a qualified additively manufactured component; by identifying a qualified additively manufactured component, the certification terms of strength, deformation and structural compliance are verified; wherein, the verification of the finished part of the component includes the verification of product quality, strength and 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 and performance stability of the component test piece;

[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 them as an additive manufacturing system.

[0023] Optional verification of finished components includes:

[0024] Conduct verification tests on finished components under real service loads on full-scale components, including non-destructive testing, mechanical and physical property testing and / or functional testing.

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

[0026] Optionally, the method further includes:

[0027] For any two parts with partially identical failure modes, after determining the available manufacturing solution for one of the parts, a supplementary test piece verification operation shall be performed on the other part using the available manufacturing solution to determine whether the available manufacturing solution is an available manufacturing solution for the other part;

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

[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 the parts and components and the applicable airworthiness requirements. The verification plan is used to verify the test pieces of the parts and components manufactured using the additive manufacturing technology, and a usable manufacturing plan that meets the requirements and can couple the verification of the material and manufacturing method provisions is obtained. In this way, the failure mode and design of the parts and components manufactured using the additive manufacturing process are associated with the additive manufacturing technology that couples the verification of the material and manufacturing method provisions, achieving the effect of simultaneously verifying the material and manufacturing method provisions.

[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 clauses without having to verify 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. They are applicable to the airworthiness compliance verification of civil aircraft parts and aviation parts such as helicopters, military aircraft, and aircraft engines manufactured using additive manufacturing processes, including but not limited to. They 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 following briefly describes the drawings required for use in the embodiments of this specification or the prior art description. Obviously, the following only describes the drawings required for use in some embodiments of this application. For those of ordinary skill in the art, other drawings can be derived from these drawings without inventive effort.

[0036] Figure 1 It is a flowchart 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 conformity of a single additively manufactured component of a civil aircraft in an embodiment of this specification.

[0038] Figure 3Schematic diagram of the airworthiness compliance verification process for 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 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 based on the embodiments in the specific implementation methods by those skilled in the art without making creative work should fall within the scope of protection of this application.

[0042] The embodiments of this specification provide a method for verifying the airworthiness compliance of a single additively manufactured component for a civil aircraft. The execution entities of the embodiments include, but are not limited to, any materials, parts, components, onboard equipment, or software used in, or intended for use and installation on, a civil aircraft. This means that the execution entities can be diverse and can be set, used, or changed as needed. Furthermore, a third party may assist the execution entity in executing the embodiments. For example, the main manufacturer or supplier may execute the verification plan and / or new manufacturing plan described in the embodiments, thereby assisting the authorities and reviewers in executing the method for verifying the airworthiness compliance of a single additively manufactured component for a civil aircraft described in the embodiments.

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

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

[0045] In this embodiment, component failure modes and design can be determined based on reference information about civil aircraft. The content of the reference information is not limited, as long as it helps determine the component failure mode and design. For example, civil aircraft reference information includes, but is not limited to, aircraft operating conditions and load conditions, component functions, characteristics, and design requirements.

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

[0047] The failure modes of the components include, but are not limited to, those caused by static loads. The specific failure modes of the components can be further determined, including, but not limited to, tensile failure, compression failure, shear failure, instability failure, and hole extrusion failure. The failure modes determined may vary for different components, and the embodiments are not limiting. The components described in the embodiments include, but are not limited to, static strength-driven additively manufactured components, i.e., components that primarily bear static loads, bear no or only negligible fatigue and damage tolerance loads, and whose damage will not affect the safety of the civil aircraft.

[0048] In an embodiment, a verification plan for a component can be established based on the component's failure mode, design, and applicable airworthiness requirements. A "verification plan" here can be a set of verification indicators and methods, including verification methods and acceptance criteria. Each component can have its own corresponding verification plan. When establishing a verification plan, in addition to the component's failure mode, design, and applicable airworthiness requirements, the component's function, characteristics, or other reference factors may also be considered, without limitation in the embodiment.

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

[0050] The verification plan may include the component type, structure, load, material, geometry, new manufacturing plan, verification method, and acceptance criteria determined based on the failure mode, design, and applicable airworthiness requirements. The specific failure mode of the component includes, but is not limited to, failure mode caused by static load.

[0051] The validation plan may include verification methods and acceptance criteria for demonstrating the performance and stability of the AM raw materials used to manufacture the component test pieces and finished parts. Specifically, the AM raw material performance and stability indicators include, but are not limited to: the chemical composition of the metal powder or wire raw material; the powder's particle size distribution, flowability, tap density, and bulk density; the wire's external dimensions and tolerances, appearance quality, and key control parameters of the production process.

[0052] The validation plan may include verification methods and acceptance criteria for demonstrating the performance and performance stability of the additive manufacturing equipment used to manufacture test and finished parts. Specifically, the performance and performance stability indicators of the additive manufacturing equipment include, but are not limited to, build dimensions, build accuracy, the accuracy and stability of key components, the accuracy and stability of control software, and the accuracy and stability 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, performance stability index, and acceptance criteria for the component used for verification shall be determined by the component's failure mode and design, as well as applicable airworthiness requirements.

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

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

[0056] S103: Performing test piece verification operations in rounds, each round of test piece verification operations including: 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 the component finished product; by identifying one of the available manufacturing schemes, coupling verification of material and manufacturing method clauses; wherein, the component is a component to be manufactured using an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes 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:

[0058] For any component, a new manufacturing plan for the component (hereinafter referred to as the "new manufacturing plan") 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 piece manufactured by the new manufacturing plan (i.e., the test piece corresponding to the selected type, geometric dimensions, sampling quantity, test method, material and / or performance, performance stability index, and acceptance standard of the component in the verification plan) is verified according to the verification plan corresponding to the component to obtain the verification result. Among them, according to the requirements of the verification plan, the component test piece can be subjected to various verifications including but not limited to material and / or performance and performance stability verification to verify the material and / or performance and performance stability of the component test piece. Specifically, the component test piece 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 test results (which belong to verification results).

[0060] If the verification result (i.e., the test piece verification result) does not meet the first preset condition (the first preset condition may be included in the verification plan, for example, the first preset condition may be a preset verification method and acceptance criteria, including acceptance standards, used to indicate the material and / or performance and performance stability of the component test piece), the next round of test piece verification will be carried out according to the above steps. In other words, a new manufacturing plan for the component will be determined; the component test piece manufactured using the new manufacturing plan will be verified according to the verification plan, and a determination will be made as to whether the verification result meets the first preset condition.

[0061] If the verification results (i.e., the results of the test piece verification) meet 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 operations will be used as the available manufacturing plan for manufacturing the finished component. After the available manufacturing plan is determined, the next round of test piece verification operations can be temporarily suspended.

[0062] As can be seen from the above, after one or more rounds of test piece verification operations, a usable manufacturing solution can be obtained after a certain round of test piece verification operations. The usable manufacturing solution can be regarded as a qualified manufacturing solution capable of manufacturing the finished component. Among them, the usable 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. The additive manufacturing system can be regarded 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 material 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 component manufactured by the latest available manufacturing plan according to the verification plan; 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 plan, 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 part of the component as a qualified additively manufactured component; by identifying a qualified additively manufactured component, verify the certification terms of strength, deformation and structural compliance; wherein, the verification of the finished part of the component includes the verification of product quality, strength and 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:

[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 dimensions, 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 component non-destructive testing, mechanical and physical performance testing and / or functional testing results (which belong to the verification results).

[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 for indicating the product quality, strength and deformation and structural compliance of the finished part, including the acceptance standard), then the above-mentioned test piece verification operation is performed again in rounds to obtain a new available manufacturing plan again, and the next round of finished part verification operation is performed.

[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 the product obtained is a qualified additively manufactured component 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 simultaneously verifying the material and manufacturing method clauses. Therefore, by identifying a qualified additively manufactured 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 the need to verify the strength performance and design value clauses of the material. Therefore, the airworthiness compliance verification results of the corresponding additively manufactured component 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 additively manufactured component, as well as the verification results of the strength, deformation and structural compliance clauses).

[0070] As can be seen from the above, through one or more rounds of finished part verification operations, a finished component that passes airworthiness conformity verification can be obtained after a certain round of finished part verification operations. Furthermore, the available manufacturing plan for producing "a finished component whose verification result meets the second preset condition" is determined as the target manufacturing plan for manufacturing the component.

[0071] In the above content, for any round of test piece verification operation, the new manufacturing plan obtained in 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 may be partially applicable to component B; the verification solution established for component B may be partially applicable to component C.

[0074] After one or more rounds of test piece verification operations, a usable manufacturing solution for manufacturing component A is obtained. This usable manufacturing solution can be used to manufacture the finished product of component A, but it may not be suitable for manufacturing the finished product of component B (because the failure modes of components A and B are partially the same). Therefore, based on the usable manufacturing solution 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 is performed on component B. During the test piece verification operation, this usable manufacturing solution is used as the new manufacturing solution for manufacturing component B, and the selected type of compression test piece of component B is verified. Based on whether the verification result meets the first preset condition (the content of the first preset condition may be different for different types of components), it is determined whether the usable manufacturing solution is the usable manufacturing solution for component B.

[0075] If the test results meet the first preset condition, then the available manufacturing solution is an available manufacturing solution for component B. This available manufacturing solution can also be used to manufacture the finished product of component B. This available manufacturing solution has passed the test piece verification operations for both components A and B. Furthermore, since the failure modes of components B and C are identical, this available manufacturing solution can also be used as an available manufacturing solution for component C. This available manufacturing solution can also be used to manufacture the finished product of component C. This available manufacturing solution has passed the test piece verification operations for both components B and C.

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

[0077] The following example further illustrates the airworthiness compliance verification method for a single additively manufactured civil aircraft component:

[0078] Taking the additively manufactured parts of civil aircraft as aircraft parts, more specifically the titanium alloy gooseneck hinge parts of civil aircraft manufactured by selective laser melting as an example, based on the working conditions and load conditions of the civil aircraft, the functions, characteristics and design requirements of the gooseneck hinge parts, it is determined that 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 using the additive manufacturing process (such as selective laser melting) is the failure mode caused by static load, and the "failure mode of the part and the design, applicable airworthiness requirements" are determined. 1 In this example, the aircraft part is a titanium alloy gooseneck hinge part to be manufactured using the selective laser 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 part 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] Among them, 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 requirements1, 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 based on the above failure mode and design and applicable airworthiness requirements.

[0081] The verification plan 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) are used to demonstrate the performance and performance stability of the raw materials used to manufacture titanium alloy gooseneck hinge parts by selective laser melting. The raw material is titanium alloy powder (such as Ti-6Al-4V), and the verification indicators for the raw material performance and performance stability include but are not limited to the chemical composition of the titanium alloy powder, the particle size distribution of the powder, flowability, 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, the verification method and acceptance criteria (including but not limited to verification indicators and acceptance standards) are used to demonstrate the performance and performance stability of additive manufacturing equipment used for selective laser melting to manufacture titanium alloy gooseneck hinge parts. Among them, the additive manufacturing equipment is a selective laser melting printing device (such as EOS M280), and the verification indicators for 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 selective laser melting equipment, accuracy and stability indicators of the control software, and accuracy and stability indicators of key process parameters.

[0083] The verification plan 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 demonstrating the material and / or performance and performance stability of component test pieces (such as tensile test pieces) manufactured by the selective laser melting process, that is, the first preset condition; wherein, the type of component test piece used for verification is a 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; it is the verification method and acceptance criteria for demonstrating the product quality, strength and deformation and structural compliance of the finished component part (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. The new manufacturing plan includes an additive manufacturing plan. 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 a titanium alloy gooseneck hinge part is specifically determined. The new manufacturing scheme includes an additive manufacturing scheme and corresponding post-processing schemes (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, i.e., a tensile test piece, can be manufactured to demonstrate the material and / or performance and performance stability of the component test piece manufactured by the laser selective melting process. Of course, a suitable heat treatment process can also be selected to heat treat the tensile test piece, and a suitable machining process can be selected to machine the tensile test piece to achieve the required surface quality and dimensional accuracy requirements of the tensile test piece, so as 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 test 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 (which belong to verification results) can be obtained.

[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 for 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 conduct a verification test on the test piece manufactured by the re-determined new manufacturing scheme to obtain the verification results. In this example, if the test results obtained by the tensile test of 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, elongation, etc. used to indicate the performance and performance stability of the tensile test piece manufactured using the laser selective melting process), then 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 in 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 the 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, elongation, etc. 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 in 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 one or more rounds of test piece verification operations mentioned above, it is ensured that the available manufacturing solution obtained can be used as a qualified manufacturing solution capable of manufacturing the finished component. In this example, the material and / or performance and performance stability obtained through one or more rounds of tensile test piece verification operations meet the requirements of the titanium alloy gooseneck hinge part verification solution. This available manufacturing solution has the ability to manufacture full-size samples of titanium alloy gooseneck hinge parts. By identifying an available manufacturing solution, it is possible to couple the verification of material and manufacturing method clauses (such as 23.603, 25.603, 23.605, 25.605).

[0089] The latest available manufacturing solutions (including additive manufacturing solutions) can be used to manufacture corresponding finished parts and components, which are used to verify the product quality, strength, deformation, and structural compliance of the finished parts and components produced through additive manufacturing processes. In this example, the corresponding full-size sample of the titanium alloy gooseneck hinge part is manufactured through the available manufacturing solutions determined above. 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 titanium alloy gooseneck hinge part. This is used to verify the product quality, strength, deformation, and structural compliance of the finished titanium alloy gooseneck hinge part produced through the selective laser melting process.

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

[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 and continue to the next round of finished part verification operation. In this example, if the test results of the full-size component verification test of the titanium alloy gooseneck hinge finished part 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 finished part manufactured by the laser selective melting process), the manufactured titanium alloy gooseneck hinge finished part will be determined to be an unqualified additive manufacturing part, and the available manufacturing solution obtained above will still be deemed unusable, and it is necessary to continue to perform the test piece verification operation in rounds and obtain a new available manufacturing solution.

[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" will be determined as the target manufacturing scheme for manufacturing the said parts. In this example, if the test results of the full-scale verification test of the titanium alloy gooseneck hinge finished 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 finished parts manufactured by the laser selective melting process), then the manufactured titanium alloy gooseneck hinge finished parts will be identified as a qualified additive manufacturing part, and the available manufacturing scheme obtained above will be determined as the target manufacturing scheme for manufacturing the titanium alloy gooseneck hinge parts.

[0093] This example demonstrates that the technical solution of the embodiment results in a qualified AM component whose product quality, strength, deformation, and structural conformity meet the requirements of the validation scheme. This utilizes the latest available manufacturing solution, enabling simultaneous verification of both material and manufacturing method requirements. Therefore, by identifying a qualified AM component, the strength, deformation, and structural conformity certification requirements can be directly verified, without requiring verification of the material's strength performance and design value requirements. For example, in this example, by identifying a qualified titanium alloy gooseneck hinge component manufactured using the selective laser melting process, the strength, deformation, and structural conformity certification requirements (e.g., 23.305, 25.305, 23.307, 25.307) can be directly verified, without requiring verification of the material's strength performance and design value requirements (e.g., 23.613, 25.613). Furthermore, this example demonstrates the application of the embodiment in the trial production and airworthiness conformity verification of AM components for civil aircraft using the titanium alloy selective laser melting process, demonstrating the feasibility of the technical solution of the embodiment.

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

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

[0096] A verification plan is established based on the failure mode and design of the parts and applicable airworthiness requirements. The test pieces and finished parts manufactured using additive manufacturing technology are verified through the verification plan to obtain a target manufacturing plan that meets the requirements and can couple the verification of material and manufacturing method clauses. The failure mode and design of the parts manufactured using the additive manufacturing process are 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 the parts, and the effect of simultaneously coupling the verification of material and manufacturing method clauses is achieved.

[0097] 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 component, 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, design, and applicable airworthiness requirements of the component, as well as the component type and structure, load, material, geometric dimensions, new manufacturing scheme, verification method, and acceptance criteria for verification determined based on the failure mode, design, and applicable airworthiness requirements, verification method and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing raw materials, verification method and acceptance criteria for demonstrating the performance and performance stability of additive manufacturing equipment, verification method and acceptance criteria for demonstrating 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 demonstrating the product quality, strength, deformation, and structural compliance of component finished parts (i.e., the second preset condition), ensuring the feasibility and richness of verification operations for test pieces and finished parts.

[0098] During the test piece verification operation, a new manufacturing plan is used to manufacture test pieces of selected types, geometric dimensions, sampling quantity, test methods, materials and / or performance, performance stability indicators, and acceptance criteria determined by the failure mode and design of the components and applicable airworthiness requirements. 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 property 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 full-size finished parts manufactured using available manufacturing solutions under actual 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 the need to verify the strength properties of the material and the design value clauses of the material.

[0100] In view of the strong coupling between raw materials, printing equipment, and printing parameters during the additive manufacturing process for civil aircraft parts, as well as the material anisotropy and structural inhomogeneity of the finished parts, this embodiment first couples and verifies the material and manufacturing method clauses, then directly verifies the strength, deformation, and structural compliance clauses, eliminating the need to verify the material's strength properties and design value clauses. This technical solution significantly reduces the cost of establishing material strength properties and design values.

[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. They are applicable to the airworthiness compliance verification of civil aircraft parts and helicopters, military aircraft, aircraft engines and other aviation parts manufactured using additive manufacturing processes, 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 in a fast, efficient and low-cost manner.

[0102] The foregoing is merely an embodiment of the present invention and is not intended to limit the present application. For those skilled in the art, various modifications and variations may be made to the present application. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present application should be included within the scope of the claims of the present application.

Claims

1. A method for verifying the airworthiness conformity of a single additively manufactured component of a civil aircraft, characterized in that: The method comprises: Determine the failure mode and design of the component based on reference information of civil aircraft, and establish a verification plan for the component based on the failure mode and design and applicable airworthiness requirements; Performing test piece verification operations in rounds, each round of test piece verification operations including: 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 the component finished product; coupling verification of material and manufacturing method clauses by identifying one of the available manufacturing schemes; wherein, the component is a component to be manufactured using an additive manufacturing process, the new manufacturing scheme includes an additive manufacturing scheme, and the verification of the component test piece includes verification of materials and / or performance and performance stability; Performing finished part verification operations in rounds, each round of finished part verification operations including: verifying the finished component manufactured using the latest available manufacturing solution according to the verification solution; if the verification result does not meet the second preset condition, performing the test piece verification operation again in rounds to obtain a new available manufacturing solution, and performing the next round of finished part verification operations; if the verification result meets the second preset condition, determining the airworthiness compliance verification result of the component, and identifying the finished component as a qualified additively manufactured component; upon identifying a qualified additively manufactured component, verifying the certification terms of strength, deformation, and structural compliance; wherein the verification of the finished component includes verification of product quality, strength, deformation, and structural compliance; 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 and performance stability of the component test piece; the second preset condition is a verification method and acceptance criteria for indicating the product quality, strength and deformation, and structural compliance of the component finished product; 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 the same as an additive manufacturing system; Verification of finished parts includes: conducting full-scale verification tests on finished parts under real service loads, including non-destructive testing, mechanical and physical property testing, and / or functional testing; The available manufacturing solution for producing a component finished product whose verification result meets the second preset condition is the target manufacturing solution for producing the component.

2. The method according to claim 1, wherein 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, wherein 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, wherein 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, wherein The method further comprises: For any two parts with partially identical failure modes, after determining the available manufacturing solution for one of the parts, a supplementary test piece verification operation shall be performed on the other part using the available manufacturing solution to determine whether the available manufacturing solution is an available manufacturing solution for the other part; For any two components with exactly the same failure modes, after determining the available manufacturing solution for one of the components, the available manufacturing solution is used to perform a finished product verification operation on the other component to determine whether the available manufacturing solution is the target manufacturing solution for the other component.

6. The method according to any one of claims 1 to 5, characterized in that For any round of test piece verification operation, the new manufacturing plan obtained from this round of test piece verification operation is different from the manufacturing plan obtained before this round of test piece verification operation.

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