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Category: Technology

May 05 2020

Improving Fatigue Life of Metal AM parts

High-Cycle Fatigue (HCF) is one of the most critical issues in mechanical engineering: from the first studies on railway axles to the infamous De Havilland Comet, this phenomenon led to some of the most tragic failures in the history of mechanics. Centuries of science and investigation led to a much better understanding of fatigue life […]

November 12 2019

Lattices – Why they enhance internal geometries

3D metal printing allows users to create very intricate forms easily. By tinkering with the internal geometries of printed parts they can achieve impressive mechanical properties. One of the best ways to achieve good strength-to-weight ratios, desirable shock and sound absorption and larger surface areas is to print objects with lattice structures. Why Lattices? What […]

November 12 2019

2D vs 3D x-ray digital scanning: a complex choice between two complementary techniques

The continuous increase in complexity and size of 3D printed parts requires a careful analysis of the methodologies used to verify their integrity. Among these, special importance is covered by X-ray inspections. Traditionally, without destructive testing, full metrology has only been performed on the exterior dimensions of components, such as with a coordinate-measuring machine (CMM) […]

November 12 2019

We have successfully implemented Scalmalloy, ductile as titanium, light as aluminium

Materials engineers perfectly know the potential of scandium as an alloying ingredient in aluminium alloys. At the end of the 50s, Soviet scientists developed the first scandium-containing alloys, aeronautic engineers learned what scandium could do to aluminium and implemented it on MiG-21 jet fighters, the most-produced supersonic jet aircraft in aviation history, and subsequently on […]

July 22 2019

Redesigned for Additive Manufacturing: serial production of a new fuel swirler for Siemens gas turbine

Whilst the principles of Design for Additive Manufacturing (DfAM) may suggest ‘clean-sheet’ components are the best way to reap the benefits of AM technology, many examples of redesigns have brought significant performance and economic benefits. In this article, Ray Huff and Terry Wohlers report on further success at Siemens in the use of AM for […]

June 16 2019

Scalmalloy is too expensive and design optimisation only makes sense in aerospace. True or false?

Additive Manufacturing is not a cheap production process. The software, machine time, materials and expertise required to make the most of the technology all come at a significant cost. The resulting financial pressures may give rise to the temptation to select a material on its price and view advanced topology optimisation as a luxury. As […]

May 10 2019

Bugatti reveals range of metal AM components developed for its high-performance sports cars

The high-performance sports car manufacturer, Bugatti Automobiles S.A.S, headquartered in Molsheim, France, is reported to be using Additive Manufacturing to develop and build a number of functional compo­nents for its iconic range. In addition to a previously announced brake caliper, which entered vehicle trials in the first half of 2018, the company has used AM […]

February 02 2019

Binder Jet metal Additive Manufacturing: process chain considerations when moving towards series production

With the launch of a number of new systems targeting the series production of components, Binder Jetting is generating a high level of interest in the world of metal Additive Manufacturing and beyond. In the following report, Sebastian Boris Hein, Claus Aumund-Kopp and Bastian Barthel of Fraunhofer IFAM review the main process considerations and production […]

December 10 2018

Binder Jetting and FDM: a comparison with Laser Powder Bed Fusion and Metal Injection Moulding

In recent years there has been a surge in interest in the use of Binder Jetting and Fused Deposition Modelling for the production of low to medium volumes of metal additively manufactured parts. In the following report, Maximilian Munsch, Matthias Schmidt-Lehr and Eric Wycisk of Ampower GmbH & Co. KG, Hamburg, Germany, review how the […]

November 25 2018

Siemens metal AM gas turbine burner completes successful first year of operation

The first gas turbine burner to be produced by Siemens using Laser Powder Bed Fusion (LPBF) metal Additive Manufacturing has now been in operation for over 8,000 hours, having completed its first full year of active service in an SGT-700 gas turbine at E.ON’s combined cycle power plant in Philippsthal, Germany. To-date, Siemens stated that […]