The control fin is a key component in a guided missile's propulsion system, stabilizing the missile's attitude and maintaining its flight trajectory under high-speed conditions. Such components demand high mechanical strength and thermal stability. However, traditional control fin designs have primarily focused on external geometry, overlooking opportunities to enhance performance through internal structural design.To address this limitation, this study proposes a design approach that integrates lattice structures within the control fin using metal additive manufacturing. A body-centered cubic (BCC) lattice was selected, with strut diameter and unit cell aspect ratio defined as the primary design variables. Finite element analysis in Abaqus was used to evaluate structural behavior, analyzing stress and displacement distributions based on variations in these lattice parameters. Manufacturability and lightweight characteristics were also assessed. Results indicate that increasing the strut diameter improves structural stability, with stress predominantly concentrated near lattice joints. Building on these findings, a non-uniform lattice design, derived from the uniform lattice analysis, was applied, demonstrating improved stress distribution and overall structural performance. This approach shows that lattice-based internal structures, enabled by metal additive manufacturing, can significantly enhance the structural performance of guided missile control fins while achieving substantial weight reduction.
Metal additive manufacturing using electron beam melting (EBM) process applies electron beam for heating, sintering, and melting of powders to fabricate a three-dimensional component. The component may contain residual porosity internally and may be subjected to poor surface finish externally. To improve the quality of the surface finish and densification, re-melting is conducted. The purpose of this paper was to estimate the appropriate process conditions for a plasma electron beam remelting process using heat transfer finite element analyses (FEAs). The impact of the travel speed of table and thickness of the deposited part on temperature distributions were examined. The size of molten pool was estimated from the results of the thermal FEA. From the estimated size of molten pool, the travel speed of table and the hatch spacing between remelting tracks are discussed and selected as the appropriate process conditions for electron beam re-melting process from the perspective of minimum overlapping region of the molten pool.
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Investigation of elimination of powder spreading in manufacture of thin and wide preheating beads from Co–Cr alloy powders using a P-ebeam Ho-Jin Lee, Dong-Gyu Ahn Journal of Materials Research and Technology.2021; 14: 1873. CrossRef
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