A Study on Failure Mitigation Through Defect Cause Identification and Microstructural Analysis of Defective Regions in Large-Scale L-PBF Metal Additive Manufacturing

In this study, for the production of an integrated head part measuring 500 ㎜ for a 35-ton engine combustor, we analyzed cases of failures between manufacturing processes. These failures included secondary design issues such as support design, as well as problems caused by heat accumulation in areas with a large surface area, which is characteristic of large parts. Through this analysis, we identified the causes of issues arising between processes when applying large-area technology to the production of large components such as combustors. Additionally, we conducted research to optimize the manufacturing process of large parts and enhance process reliability by analyzing the causes of output failures that occur during the production of 500 ㎜-class large metal components.