some of the most recent technical news related to additive manufacturing
In recent years, additive manufacturing (commonly known as "3D printing") technology has made a splash in the aerospace, automotive, home appliance, medical, and consumer electronics sectors by significantly reducing R&D costs, shortening R&D cycles, saving energy, and improving design freedom and product manufacturing efficiency.
As a publisher of COPE and ICMJE standards and guidelines, InnovationForever dedicates to providing a high-quality platform for scholarly communication among researchers, authors and readers around the world. IJAMS welcomes short and full review articles, as well as research articles, letters, short communications, experimental data, software, hardware and technical descriptions to discuss technologies, developments, applications, challenges and limitations, but only in the specific area of additive manufacturing.
This article lists some of the most recent technical news related to additive manufacturing, and we welcome your contributions.
Additive manufacturing - the impact of it on the aerospace industry can't be overestimated. No other technology has attached so many companies to enter the industry and allow to deliver products such as rockets in such a short period of time and at such a low cost.
Turbopump components in rocket engines are typically cast, forged and welded, and the tooling required for these processes increases development costs and reduces flexibility in design iterations. Thanks to additive technologies, we can fabricate turbopumps using 3D printing, which lowers costs and allows for increased innovation through iterations between each prototype.
Under traditional aerospace manufacturing methods, it takes 9 to 12 months of lead time and huge costs to build and test the molds. Additive manufacturing allows us to place a new design on a test bed, make modifications to it and print it quickly, and then launch the product in a matter of weeks. 3D printing has had a short history in the space industry since SpaceX launched its 3D printed rocket engine in 2013.
Metal 3d printing
The historical foundation of additive manufacturing (AM) dates back almost 150 years, when two-dimensional layers were used to overlay to shape topographical maps in three dimensions. In the late 2000s, AM technology for metals stood out among the many AM technologies , becoming the focus of market attention.
Metal additive manufacturing technologies have evolved to date and can be simply divided into two broad categories according to the supply of their raw materials: powder-laying 3D printing technologies, such as selective laser melting (SLM) and powder-feeding additive manufacturing technologies; and powder-bed 3D printing technologies, which can also be subdivided into devices that directly melt metal for molding and technologies that spray binder bonding for molding followed by sintering treatment.
Despite the impressive results achieved, additive manufacturing of metals is far from being a mature manufacturing technology, and there are still many issues and challenges to be solved, as well as many industrial applications to be explored.
3D printed nickel single crystal
NIMS and Graduate School of Engineering of the Osaka University have successfully used 3D printing to produce nickel single crystals with few crystal defects by irradiating nickel powder with a large radius flat-top laser beam.
Using a commercial SLM 280 3D printer, the NIMS- Graduate School of Engineering of Osaka University research team successfully fabricated single crystals using a flat-top laser beam, creating a flat melt pool surface on nickel powder. The single grains grew in the same direction, with fewer strain-induced defects. Single crystals without grain boundaries are prone to cracking and are very strong at high temperatures.
Jet engine and gas turbine components are becoming more complex in shape and lighter in weight, and the demand for additive manufacturing of these components using heat-resistant nickel-based high-temperature alloys is growing. Since single crystals are stronger than polycrystals at high temperatures, their practical application as heat-resistant materials is promising. Global R&D efforts to achieve this goal using cheaper and widely available laser additive manufacturing technologies are expected to intensify rapidly.
AM Center Expansion
Last week, Collins Aerospace's Additive Manufacturing Center in West Des Moines, Iowa, was further expanded. This will allow Collins to make room for additional 3D metal printers. The new machines will be used to enhance current production capabilities and expand their portfolio of metals used to additively produce engine parts on site.
With this expansion, they will significantly increase their additive manufacturing capabilities and enhance their ability to produce more parts faster for airframe and engine customers. Additive manufacturing offers several key advantages over traditional manufacturing, as optimized designs not only reduce costs, but also significantly reduce lead times. Additives also allow us to produce lighter parts to reduce aircraft fuel consumption and carbon emissions, which is key to more sustainable flight.
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