Case studies

Here some examples of pieces realized with Prima Additive machines.

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Aviation turbine blades

Type of application:

Case Description:

The prototype of a turbine – part of aerospace components – was build with aim to evaluate the powder-bed technology capabilities on Print Sharp 250. A series of experimentation on the material and the process was performed with target to balance build time and quality. The results were assessed leading to promising conclusions on the possibility of spare parts to be manufactured by PA for future use.

Industrial sector:

Aerospace

Process information:

  • Material = Inconel 718
  • PSD = 20-50 µm
  • Layer thickness = 30 µm
  • Inert gas = Nitrogen
  • Building rate = 14 cm3/h
  • Hardness = 30 HRC
  • Density >99%
  • Roughness Ra = 17 µm

Aero-engine case

Type of application:

Case Description:

A demanding application due to the material that was needed to be used. Therefore, attention was paid not only on the process parameters but also on the scanning strategy (remelting option f the upper layer). Volume and upskin parameters were also important for this case due to the shape of the part. Inert gas flow was regulated for a “clean” processing area.

Industrial sector:

Aerospace

Process information:

  • Material = TC4
  • PSD = 20 – 50 µm
  • Layer thickness = 30 µm
  • Inert gas = Argon
  • Building rate = 12 cm3/h
  • Hardness = 300 HV
  • Density >99%
  • Roughness Ra = 12 µm

Small scale impeller

Type of application:

Case Description:

The small scale version of an impeller was printed in Print Sharp 250. The accuracy required for the realization of the interior was handled by selection of specific process parameters and the decreased layer thickness. The results of printing a so small component was more than satisfying extending the capabilities of the process with Print Sharp 250.

Industrial sector:

Demonstrative geometry

Process information:

  • Material = AISI 316L
  • PSD = 20-50 µm
  • Layer thickness = 20 µm
  • Inert gas = Nitrogen
  • Building rate = 14 cm3/h
  • Hardness = HRC
  • Density >99%
  • Roughness Ra = 11 µm

Bracket

Type of application:

3D fabrication

Case Description:

A special process parameter set for TC4 was created and a prototype of the reported part was printed on the Print Sharp 250. The part was topological optimized while the superficial and mechanical characteristics were very satisfactory. Special care was given on the parameters selection of upskin.

Industrial sector:

Aerospace

Process information:

  • Material = TC4
  • PSD = 20 – 50 µm
  • Layer thickness = 30 µm
  • Inert gas = Argon
  • Building rate = 13 cm3/h
  • Building time = 5 hours
  • Density >99%
  • Roughness Ra = 12 µm

Twisted tower

Type of application:

Case Description:

Reported case is a demonstrative geometry. Tower is designed with a complete 90° rotation of the walls, meaning a gradual rotation <1° per layer. This is an important aspect because LMD process builds only auto-supported structure. The complete assembly is an example of nesting solution, in which four towers, with minimum distance, are built in the same job. LMD allows the nesting of different structures with a minimum distance around 10 mm without interaction and defects on each single element

Industrial sector:

Demonstrative geometry

Process information:

  • Material = AISI 316L (stainless steel)
  • PSD = 50-150 µm
  • Geometry size = 25x25x100 mm3
  • Linear energy density = 30 J/mm
  • Powder flow = 8 g/min
  • Building rate = 25 cm3/h
  • ΔZ = 0.25 mm
  • Building time = 75 min
  • Density > 99%
  • Roughness Ra = 15 µm

Turbine Blade

Type of application:

Case Description:

Realization of a turbine blade as demonstrative geometry: typical example of powder bed production. Hollow structure with walls realized by multi-passage deposition. Critical aspects related to the software interpolation in realization of the curve and finishing surface (smooth and homogeneous).

Industrial sector:

Aerospace

Process information:

  • Material = AISI 316L (stainless steel)
  • PSD = 50-150 µm
  • Geometry size = 74x54x40 mm3
  • Linear energy density = 36 J/mm
  • Powder flow = 8 g/min
  • Building rate = 15÷20 cm3/h
  • Building time = 90 min
  • Density >99%
  • Roughness Ra = 25 µm