Question (Total: 100 marks) Additive Manufacturing (AM) is gradually gaining acceptance in the aerospace manufacturing industry. AM is able to produce parts with weight saving, complex geometry and material range. Therefore, it offers a good solution for creating light and strong aerospace parts. In August 2013, NASA has tested an SLM printed rocket injector during a hot fire te generates 20,200 pounds of thrust. In 2015, the FAA cleared the first 3D printed part for the use in a commercial jet engine. CFM LEAP Engine featured 19 3D printed fuel nozzles. At the 2017 Paris Airshow, FAA certified, BOEING 787 displayed structural parts fabricated from titanium wire. GSE Aerospace Pte Ltd is evaluating the options to manufacture some of their aerospace parts through traditional (subtractive processes) or AM technologies involving both metal and plastics. 1. Formulate FOUR (4) conditions that would favour Conventional and Additive manufacturing process. Favour Additive Manufacturing Favour Conventional Manufacturing 3 (16 marks) 2. The company is considering to incorporate AM into their current operation. Appraise FOUR (4) advantages and limitations of Additive Manufacturing (with a brief explanation). (16 marks) The company is studying to build metal components using AM systems. Appraise and briefly describe THREE (3) different additive manufacturing processes that can be used to produce aerospace metallic components. (Hint: Direct, Hybrid and In-Direct process). Identify ONE (1) common post processing needed for all of these AM process to achieve the final desired quality of the metal part and the necessary consideration that would be factored in, in the designing of the as built part. (18 marks)