Safety and reliability of metal AM parts (Authentise Weekly News-In-Review – Week 60)

3D printed metal parts are already being employed in very real world situations, from aircraft engine parts to wind turbines. In order to be applicable for these high stress scenarios, metal parts need to comply with very stringent performance standards. 3D printed brakes have been deemed suitable for a Bugatti Chiron, the most powerful super car in the company’s history. You can bet they’ve made their homework prior to putting their whole line of $3M cars on the line. Hydraulic parts manufacturers are utilizing AM to produce components faster and more efficiently than ever before, capable maintaining peak performance in highly pressurized applications. The research is still ongoing, especially in the material sciences. Scientists at the University of Kassel have been able to use AM with a particularly strong steel alloy, which will greatly enhance the safety and reliability of metal parts.

SLM Solutions Metal 3D Printing Brakes The Most Powerful Car In Bugatti History

Bugatti's

[…] 3D printing is implemented for next generation development of the Bugatti Chiron – a car with a price tag close to $3 million. Measuring 41 cm x 21 cm x 13.6 cm (L x W x H) the part claims, by volume, to be “the largest functional component” 3D printed out of titanium. It is also 2 kg lighter than its 4.9 kg machined aluminum counterpart.

“Technically, this is an extremely impressive brake caliper, and it also looks great.” – Frank Götzke, Head of New Technologies in Technical Development at Bugatti Automobiles S.A.S.

Read the full story here.

Aidro Uses Metal 3D Printing to Improve Hydraulic Components

Aidro was founded in 1982 by hydraulics engineer Paolo Tirelli. Today, they use metal 3D printing for making custom designs with complex geometries, lightweight parts, and rapid prototyping.

“With good design methods, we can 3D print a hydraulic manifold that can withstand pressure peaks in the system without any problems,” says Alberto Tacconelli, Managing Director. “We can increase the wall thickness and change the shapes of the channels where the FEM analysis indicates a potential failure.”

Read about in-depth examples at 3DPrint.

EBM 3D Printing Process Used to Process a Steel Alloy with High Damage Tolerance

For the first time, a research team at the University of Kassel in Germany has used additive manufacturing to process a steel alloy with extremely high damage tolerance, which will help in promoting safety and reliability of 3D printed metal parts. […] This type of alloy, thanks to its special deformation mechanisms, holds up very well, and the heat from the EBM process helps to avoid any unpredictable material properties, resulting in a significantly better inner material structure that protects against possible damage.

Read more about it here.

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