Process chain for the production of highly complex turbine parts
Integration of additive technologies in the manufacturing of highly stressed producer goods like turbine components.
When developing a product, companies are confronted with rapidly changing markets. For holistic production processes, it is important to analyze precisely all processes and technologies involved in the product lifecycle - from product development to production and logistics. Moreover, production processes have to be optimally synchronized with one another.
The institutes of the Fraunhofer Additive Manufacturing Alliance develop new applications by considering all current additive manufacturing technologies. In addition, we offer special systems and comprehensive hardware and software solutions for the following processes:
- Laser-based processes - metals and plastics
- 3D printing technologies - ceramics and photopolymers
- Process chains and subsequent processes
The Fraunhofer Additive Manufacturing Alliance offers you well-engineered and reproducible processes as well as individually adapted systems for your applications and products.
Due to the almost unlimited geometric freedom in design and manufacturing and in combination with new materials, implant production by additive manufacturing is becoming more and more important. The potential to simulate bone formation by means of complex internal component structures and thus save weight while maintaining mechanical strength is almost unique. Examples of the growing range of materials include proven, biocompatible light metal alloys based on titanium (Ti6Al4V) as well as well-known CoCr-based materials. In combination with new design philosophies and simulation techniques, new approaches for products - such as implants with integrated reservoirs for long-term medication - are emerging.
This is where we develop additive manufacturing processes such as Selective Laser Melting (SLM): Metallic and ceramic components respectively tools are produced by using SLM as a rapid prototyping and rapid manufacturing process.
The work of the alliance institutes includes process engineering, physical and material science basics, modelling to support and optimize process development and the development of components for beam guidance and shaping, for powder feed and for process monitoring and control. In addition, complete pilot plants are developed and installed.
The sole introduction of additive manufacturing technology into production is no longer enough. Rather, it requires a comprehensive implementation of additive logic in the entire production chain - from pre-planning and design through to further development and adaptation of systems and materials. The tasks are manifold and complex.
In addition to the core process of printing, the additive processes in production require the integration of upstream and downstream steps. These often include automated handling of materials and components, cleaning and quality control, for example using image processing systems. Process reliability and process reproducibility are central criteria in the development of new applications.
The alliance institutes develop hybrid processing technologies for the machining and sheet metal forming of difficult-to-machine materials. The process organization allows the complete machining of complex shaped components. Even with small batch sizes and a large number of variants, flexible and efficient production is possible.
The work of the alliance institutes includes the development of new applications based on customer specifications (material adaptation, geometry, cost-effectiveness, product quality and environmental conditions). This applies both the development and optimization of individual components and subsystems as well as the construction of complete production plants.