Printing as a substitute of casting How additive manufacturing revolutionises foundry know-how
Germany — 3D printing of metals is at the moment altering many manufacturing processes within the business. As a complement and various to foundry know-how, the 3DMP course of affords a possibility to fabricate even massive workpieces economically in small numbers. This doesn’t essentially should be seen as a contest — an additive manufacturing machine could possibly be a great growth of the manufacturing processes provided by foundries.
Velocity, low price and top quality — these are the important standards when evaluating the processes for the manufacturing of metallic components. Relying on the quantity, measurement and complexity of the parts in addition to the chosen metallic, completely different manufacturing processes are appropriate. Additive processes have captured new areas of utility in recent times. Powder-based 3D printing processes are most generally used. The method permits manufacturing of very effective buildings however is commonly restricted in pace and measurement. One other drawback: Powder as a fabric could be very costly and its dealing with is a relatively complicated course of.
3DMP instead and complement for foundries
Gefertec has additional developed the WAAM course of and introduced it to market maturity with its 3DMP WAAM know-how resolution (see textual content field). The arc welding course of makes use of wire because the beginning materials, which makes it doable to print even massive and heavy parts at excessive pace. For the fabric 316L, the know-how achieves a construct price of as much as 3.6 kg/h. Wire from all frequent metals – together with costly supplies resembling corrosion-resistant, heat-resistant steels or nickel-based alloys – is accessible at comparatively low costs. This makes the method considerably cheaper than powder-based 3D printing strategies. With these benefits, 3DMP lends itself as a complement to standard casting strategies. As there isn’t any want for the frilly manufacturing of fashions or molds, Gefertec machines can be utilized to supply near-net-shape blanks from metallic rapidly and cost-effectively. The ultimate processing then takes place utilizing typical processing strategies resembling turning and milling — a step that can be vital after casting, relying on the required floor high quality of the element. One other optimistic facet of producing parts utilizing 3DMP is the smaller CO2 footprint. The appreciable quantity of power required for casting will be lowered by as much as two thirds utilizing 3DMP.
The revolutionary additive manufacturing course of permits the manufacturing of high-quality parts. The fabric properties correspond to these of casting parts and even exceed them (see desk above). Through the use of certified course of parameters and built-in monitoring in the course of the course of, formation of cavities or porosity within the parts will be excluded. 3DMP exhibits its superiority particularly in small portions and by making utilization of supplies which might be troublesome to course of or are costly. Typical examples embrace nickel-based alloys, chrome steel or hot-work metal.
Feasibility research as a service
Adopting new applied sciences is a giant step for many corporations. Particularly when expertise is missing, these accountable usually shrink back from the associated investments. Gefertec has due to this fact arrange an Utility Heart on the firm’s headquarters in Berlin, Germany to fabricate parts on their arc machines and supply a variety of providers.
The Utility Heart carries out feasibility research on the usage of 3DMP manufacturing know-how, specializing in element improvement primarily based on buyer necessities. This may occasionally for instance embrace customer-specific necessities for materials testing. Following these research, the shopper can determine whether or not to put money into an arc machine or outsource the 3D printing of parts. The Utility Heart makes the outcomes obtained in the course of the research obtainable to allow a seamless switch of data, which makes feasibility research a superb alternative for a foundry to first consider the brand new manufacturing course of intimately.
If the shopper decides to outsource the printing course of, Gefertec, along with its contract manufacturing clients, affords contract manufacturing of blanks or completed parts in response to the design drawings supplied. Non-obligatory warmth therapy of the manufactured components can be doable. The supply time is only some days and relying on the fabric manufacturing prices will be lowered by as much as 30 %.
Gefertec has already performed the introduced feasibility research efficiently in a number of buyer initiatives. A venture ran for Deutsche Bahn targeted on utilizing the 3DMP course of to fabricate mobility-relevant spare components which might be not obtainable from inventory and typically had extraordinarily lengthy supply occasions. A typical element is the secondary roll cease required within the bogies of ICE trains. This element limits the transverse play of the railroad automobile physique and thus ensures the secure cornering of the trains in tight observe curves. The Utility Heart confirmed within the feasibility research that this element could possibly be manufactured in top quality on the arc machines. The precise manufacturing passed off at Rolf Lenk, a specialist in additive manufacturing. The corporate manufactured the element in a really quick time and made it obtainable to Deutsche Bahn. The very quick manufacturing occasions have a optimistic impact on the supply of the autos at Deutsche Bahn.
For one more buyer, Gefertec’s specialists investigated the manufacturing of huge rotationally symmetrical plant parts fabricated from corrosion-resistant steels which might be used, for instance in meals manufacturing or the chemical business. The method additionally impressed this producer with wonderful element high quality in addition to quicker and cheaper manufacturing. The difficulties which might be frequent with corrosion-resistant metal in different manufacturing processes don’t come up with 3D metallic printing on the arc machines.
Portfolio growth in a foundry
The 3DMP course of for additive manufacturing of metallic parts is a perfect possibility for foundries to broaden their portfolio. This course of is especially appropriate for metallic supplies which might be troublesome to course of utilizing different strategies and for the manufacturing of smaller portions. One other decisive benefit is the excessive manufacturing pace: If quick supply occasions are required, the 3DM course of is a superb various. Corporations can take a look at the brand new know-how risk-free by utilizing the providers of the Utility Heart at Gefertec. With the related data switch, foundries can combine the method step-by-step.