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Experimental and numerical modelling of defects in an additively manufactured aluminium propeller
Author(s)
Nkwanyana, Zwelisha Senzokuhle Siyanda
Date Issued
2026
Type
master thesis
Publisher
Cape Peninsula University of Technology
Abstract
This research focused on conducting a numerical analysis of stress and strain distribution of defects and experimentally validating the presence of defect in an additively manufactured aluminium alloy propeller using advanced Non-destructive testing methods. The aim of this research was to understand the additively manufactured component behaviour when there are embedded defects that mimic inherent defects. The methods of investigation were numerical modelling using ABAQUS and laboratory experiments. The simulation findings from 20 steps had observed an increase in stress distribution along the blades. An analysis of a randomly sampled blade showed the stress results to be ascending from the tip of the blade to the root at increment of 0,5 MPa however at position 15 to 17 there an abrupt change of stress distribution which suggested a concentrated stress range of 105 MPa and 137 MPa. This led to a stress concentration factor of 1.36. This area was assessed using Micro X-ray CT which suggested the presence of the linear defect. This research concludes that crack propagation of inherent defects of additive manufacturing (AM) components are significantly influenced by: • cyclic loading conditions on defective AlSi10Mg AM components, results in a crack propagating easily along the interfaces, leading to delamination or inter-layer cracking. • Stress Concentration: Linear defects (cracks) create localised stress concentrations. When the component is subjected to loading, these areas experience higher stress, which can accelerate crack initiation and growth in AlSi10Mg AM components. The solutions obtained in this research demonstrate to create a data of effect-of-defect behaviour of AM aluminium component.
Additional information
Thesis (MEng (Mechanical Engineering))--Cape Peninsula University of Technology, 2026
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Nkwanyana, ZSS_221666648 (1).pdf
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