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The purpose of this paper is to examine the mechanical behaviour of additively manufactured Ti-6Al-4V under cyclic loading. Using as-built selective laser melting (SLM) Ti-6Al-4V in engineering applications requires a detailed understanding of its elastoplastic behaviour. This preliminary study intends to create a better understanding on the cyclic plasticity phenomena exhibited by this material under symmetric and asymmetric strain-controlled cyclic loading.

This paper investigates experimentally the cyclic elastoplastic behaviour of as-built SLM Ti-6Al-4V under symmetric and asymmetric strain-controlled loading histories and compares it to that of wrought Ti-6Al-4V. Moreover, a plasticity model has been customised to simulate effectively the mechanical behaviour of the as-built SLM Ti-6Al-4V. This model is formulated to account for the SLM Ti-6Al-4V-specific characteristics, under the strain-controlled experiments.

The elastoplastic behaviour of the as-built SLM Ti-6Al-4V has been compared to that of the wrought material, enabling characterisation of the cyclic transient phenomena under symmetric and asymmetric strain-controlled loadings. The test results have identified a difference in the strain-controlled cyclic phenomena in the as-build SLM Ti-6Al-4V when compared to its wrought counterpart, because of a difference in their microstructure. The plasticity model offers accurate simulation of the observed experimental behaviour in the SLM material.

Further investigation through a more extensive test campaign involving a wider set of strain-controlled loading cases, including multiaxial (biaxial) histories, is required for a more complete characterisation of the material performance.

The present investigation offers an advancement in the knowledge of cyclic transient effects exhibited by a typical α’ martensite SLM Ti-6Al-4V under symmetric and asymmetric strain-controlled tests. The research data and findings reported are among the very few reported so far in the literature.

This viewpoint aims to increase the awareness on the demand faced by the technical sector of the Indian and Chinese aviation industry and how this can be met by the adoption of the European Aviation Safety Agency (EASA) regulatory framework.

A brief overview of the challenges that the Indian and the Chinese aviation industry is facing is provided, in terms of meeting the demand for sustainable growth. A description of the structure of the EASA framework and its main characteristics is presented, along with a focussed discussion on the framework’s applicability to the Indian and the Chinese aviation maintenance and broader continuing airworthiness sector.

The EASA regulatory framework can offer a safe and business-effective solution for the Indian and the Chinese aviation industry, aligning with world’s best practice.

A discussion in adopting the EASA framework in India and China can be helpful in increasing awareness and assisting decision makers realise that this is a possible option.

This viewpoint can be useful in provoking discussion, by summarising the key issues and points surrounding aviation regulation standardisation in India and China, along the lines of the EASA framework. Moreover, some possible ways to increase awareness around EASA in India and China are discussed from the point of view of influencing tomorrow’s decision makers.

Honeycombs enjoy wide use in various engineering applications. The emergence of additive manufacturing (AM) as a method of customisable of parts has enabled the reinvention of the honeycomb structure. However, research on in-plane compressive performance of both classical and new types of honeycombs fabricated via AM is still ongoing. Several important findings have emerged over the past years, with significance for the AM community and a review is considered necessary and timely. This paper aims to review the in-plane compressive performance of AM honeycomb structures.

This paper provides a state-of-the-art review focussing on the in-plane compressive performance of AM honeycomb structures, covering both polymers and metals. Recently published studies, over the past six years, have been reviewed under the specific theme of in-plane compression properties.

The key factors influencing the AM honeycombs' in-plane compressive performance are identified, namely the geometrical features, such as topology shape, cell wall thickness, cell size and manufacturing parameters. Moreover, the techniques and configurations commonly used for geometry optimisation toward improving mechanical performance are discussed in detail. Current AM limitations applicable to AM honeycomb structures are identified and potential future directions are also discussed in this paper.

This work evaluates critically the primary results and findings from the published research literature associated with the in-plane compressive mechanical performance of AM honeycombs.

The material extrusion (ME) process induces variations in the final part’s microscopic and macroscopic structural characteristics. This viewpoint article aims to uncover the relation between ME fabrication parameters and the microstructural and mesostructural characteristics of the ME BASF Ultrafuse Steel 316L metal parts. These characteristics can affect the structural integrity of the produced parts and components used in various engineering applications.

Recent studies on the ME BASF Ultrafuse Steel 316L are reviewed, with a focus on those which report microstructural and mesostructural characteristics that may affect structural integrity.

A relationship between ME fabrication parameters and subsequent microstructural and mesostructural characteristics is discussed. Common microstructural and mesostructural/macrostructural defects are also highlighted and discussed.

This viewpoint article attempts to bridge the existing gap in the literature, highlighting the influence of ME fabrication parameters on Steel 316L parts fabricated via this additive manufacturing method. Moreover, this article identifies and discusses important considerations for the purposes of selecting and optimising the structural integrity of ME-fabricated Steel 316L parts.

This study presents the improvements of the multicomponent Armstrong–Frederick model with multiplier (MAFM) performance through a numerical optimisation methodology available in a commercial software. Moreover, this study explores the application of a multiobjective optimisation technique for the determination of the parameters of the constitutive models using uniaxial experimental data gathered from aluminium alloy 7075-T6 specimens. This approach aims to improve the overall accuracy of stress–strain response, for not only symmetric strain-controlled loading but also asymmetrically strain- and stress-controlled loading.

Experimental data from stress- and strain-controlled symmetric and asymmetric cyclic loadings have been used for this purpose. The analysis of the influence of the parameters on simulation accuracy has led to an adjustment scheme that can be used for focused optimisation of the MAFM model performance. The method was successfully used to provide a better understanding of the influence of each model parameter on the overall simulation accuracy.

The optimisation identified an important issue associated with competing ratcheting and mean stress relaxation objectives, highlighting the issues with arriving at a parameter set that can simulate ratcheting and mean stress relaxation for load cases not reaching at complete relaxation.

The study uses a strain-life fatigue application to demonstrate the importance of incorporating a technique such as the presented multiobjective optimisation method to arrive at robust parameters capable of accurately simulating a variety of transient cyclic phenomena.

The proposed methodology improves the accuracy of cyclic plasticity phenomena and strain-life fatigue simulations for engineering applications. This study is considered a valuable contribution for the engineering community, as it can act as starting point for further exploration of the benefits that can be obtained through material parameter optimisation methodologies for models of the MAFM class.

The Airbus A320 family engine fan cowl doors (FCDs) safety issue is known to the industry for almost 18 years; however, it has not been addressed adequately by the aircraft manufacturer and the various operators and regulating authorities. The purpose of this paper is to examine in a systematic way the possible operational and safety implications of a new modification on the engine FCDs.

An array of error-prone scenarios is presented and analysed under the prism of human factors in a non-exhaustive qualitative scenario analysis.

All examined scenarios are considered more or less probable. A number of accident prevention solutions are proposed for each of the scenario examined, in view of the acceptance and implementation of this modification by operators.

As these scenarios are neither exhaustive nor have been tested/validated in actual aircraft maintenance practice, the further analysis is necessary. A substantial follow-up survey should take place, which should include a wider array of scenarios. This would allow obtaining the necessary data for a quantitative (statistical) analysis.

This case study identifies issues in relation to this modification, introduced by Airbus and the European Aviation Safety Agency (EASA), which may prove problematic from the point of view of safety effectiveness and disruption of operations.

This case study examines a long-standing aviation safety issue and the implications of a solution proposed by the aircraft manufacturer and adopted by EASA. This can be useful in increasing the awareness around these issues and highlight the importance of a human-centric and scenario-based design of engineering modifications towards minimising error in aircraft technical operations.

The wide application of metal material extrusion (MEX) has been hampered by the practicalities associated with the resulting shrinkage of the final parts when commercial three-dimensional (3D) printing equipment is used. The shrinkage behaviour of MEX metal parts is a very important aspect of the MEX metal production process, as the parts must be accurately oversized to compensate for shrinkage. This paper aims to investigate the influence of primary 3D printing parameters, namely, print speed, layer height and print angle, on the shrinkage behaviour of MEX Steel 316L parts.

Two groups of dog-bone and rectangular-shape specimens were produced with the BASF Ultrafuse Steel 316L metal filament. The length, width and thickness of the specimens were measured pre- and post-debinding and sintering to calculate the percentile shrinkage rates. Analysis of variance (ANOVA) was used to evaluate and rank the significance of each manufacturing parameter on shrinkage. Typical main print quality issues experienced in this analysis are also reported.

The shrinkage rates of the tested specimens ranged from 15.5 to 20.4% along the length and width axis and 18.5% to 23.1% along the thickness axis of the specimens. Layer height and raster angle were the most statistically significant parameters influencing shrinkage, while print speed had very little influence. Three types of defects were observed, including surface roughness, surface deformation (warping and distortion) and balling defects.

This paper bridges an existing gap in MEX Steel 316L literature, with a focus on the relationship between MEX manufacturing parameters and subsequent shrinkage behaviour. This study provides an in-depth analysis of the relationship between manufacturing parameters – layer height, raster angle and print speed and subsequent shrinkage behaviour, thereby providing further information on the relationship between the former and the latter.

Healthcare has undergone multiple phases in gaining understanding, accepting and implementing quality and safety, with the last 3 decades being crucial and decisive in making progress. During that time, safety has always been quoted along with quality, but the cost of error in healthcare (both in human lives and monetary cost) has been continuing to rise.

This article discusses the authors’ expert perspective in comparison to the industry’s research and practice outputs.

Healthcare has not yet defined quality and safety. This is allowing the misconception that already established quality management systems (QMSs) are fit for safety purposes as well. Even though aviation has acted as a paradigm for healthcare, further alignment in embedding safety management systems (SMS) has yet to be realised.

In this paper, the distinct nature of safety and its detachment of quality is being discussed, along with the need for clear and safety specific processes. Setting common language is the first step in establishing appropriate safety processes within SMSs, operating in tandem with QMSs, to promote patient safety successfully.

The ability to learn from previous events in support of preventing future similar events is a valuable attribute of aviation safety systems. A primary constituent of this mechanism is the reporting of incidents and its importance in support of developing learning material. Many regulatory requirements clearly define a structure for the use of learning material through organisational and procedural continuation training programmes. This paper aims to review aviation regulation and practice, highlighting the importance of learning as a key tenet of safety performance.

Applicable International Civil Aviation Organisation requirements and the European Union (EU) regulation in aircraft maintenance and continuing airworthiness management have been critically reviewed through content analysis.

This review has identified gaps in the European implementing rules that could be addressed in the future to support a more effective approach to the delivery of lessons in the aircraft maintenance and continuing airworthiness management sector. These include light-touch of learning and guidance requirements, lack of methodologies for the augmentation of safety culture assessment, absence of competence requirements for human factors trainers and lack of guidance on standardised root-cause analyses.

This paper offers aviation safety practitioners working within the European Aviation Safety Agency regulatory regime an insight into important matters affecting the ability to learn from incidents.

This paper evaluates critically and independently the regulation and practice that can affect the ability of EU regulated aircraft maintenance and continuing airworthiness management organisations to learn from incidents. The outputs from this research present a fresh and independent view of organisational practices that, if left unchecked, are capable of impeding the incident learning process.

Productivity is often cited as a key barrier to the adoption of metal laser-based powder bed fusion (ML-PBF) technology for mass production. Newer generations of this technology work to overcome this by introducing more lasers or dramatically different processing techniques. Current generation ML-PBF machines are typically not capable of taking on additional hardware to maximise productivity due to inherent design limitations. Thus, any increases to be found in this generation of machines need to be implemented through design or adjusting how the machine currently processes the material. The purpose of this paper is to identify the most beneficial existing methodologies for the optimisation of productivity in existing ML-PBF equipment so that current users have a framework upon which they can improve their processes.

The review method used here is the preferred reporting items for systematic review and meta-analysis (PRISMA). This is complemented by using an artificial intelligence-assisted literature review tool known as Elicit. Scopus, WEEE, Web of Science and Semantic Scholar databases were searched for articles using specific keywords and Boolean operators.

The PRIMSA and Elicit processes resulted in 51 papers that met the criteria. Of these, 24 indicated that by using a design of experiment approach, processing parameters could be created that would increase productivity. The other themes identified include scan strategy (11), surface alteration (11), changing of layer heights (17), artificial neural networks (3) and altering of the material (5). Due to the nature of the studies, quantifying the effect of these themes on productivity was not always possible. However, studies citing altering layer heights and processing parameters indicated the greatest quantifiable increase in productivity with values between 10% and 252% cited. The literature, though not always explicit, depicts several avenues for the improvement of productivity for current-generation ML-PBF machines.

This systematic literature review provides trends and themes that aim to influence and support future research directions for maximising the productivity of the ML-PBF machines.