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Chinese scientists develop first ever 3D printing, casting and forging all-in-one technique – 3ders.org (blog)

by • July 21, 2016 • 10s Comments

Jul 22, 2016 | By Benedict
A team of scientists in China has turn it intod a metal 3D printing technology called “smart micro casting & forging.” The technology combines 3D printing and forging, uses metal wire “1/10 the cost” of AM powders, and may be utilized in the aerospace, car, and molding industries.

Under the leadership of Zhang Haiou, Professor of Mechanical Engineering at Huazhong University of Science, a team of scientists in China has—after 10 years of research—turn it intod what may prove to be a game-changing form of metal building. A combination of 3D printing, casting, and forging, the new method claims to have “broken the largest obstacle facing the 3D printing industry,” delivering a disruptive technological technology to global machinery building.
Additive building is becoming a extra
and extra
talked about choice for metal parts across a wide range of industries, but doubts stay over the structural integrity of sure 3D printed components. Advocates of traditional building methods cite the porosity, lack of fusion, and other problems synonymous with 3D printed parts as a reason to stick with casting or forging techniques.
The Micro Forging & Casting Sync Composite Device, a new product turn it intod by Zhang Haiou and his team, offers an alternative to metal 3D printing methods like selective laser melting and sintering, combining 3D printing, casting, and forging in one. This amalgamation of techniques contributes to increased part durablity and toughness, improved product lifecycle, and higher reliability. According to its createers, the technology can in addition be utilized to turn it into thin-walled metal components while eliminating excess material and equipment costs.
The all-in-one micro-casting-forging-milling building equipment may already being turn it intod by the scientists can be capable of building metal forging parts up to 5.5 × 4.2 × 1.5 m in dimensions, with a surface roughness of 0.02 mm—the level of general machining processing. The team has, yet, may already turn it intod a machine capable of 3D printing in eight kinds of materials, that include titanium alloy, for aircraft and marine use, and steel, for use in nuclear power stations. This machine has created a part 2.2 m long and weighing 260 kg. It has in addition that successfully 3D printed a forging part measuring 1800 × 1400 × 50 mm.
In traditional mechanical building, cast metal can not be directly processed into high-performance parts. Its internal structure must be improved through forging, while molding problems in addition require to be solved. Large forging machinery can be costly, yet, and implementation of such equipment results in a long production process, massive energy consumption, serious pollution, and serious waste. Furtherextra
, it stays complex to create functionally gradient material parts. As a burgeoning technology, conventional metal 3D printing technology can solve the above shortcomings of the traditional process, building it a valuable technology in the aerospace, car, and molding industries.
Zhang Haiou commented: “In the past, conventional 3D printing has been fatally flawed in the next areas: initially, without forging, metal parts have a serious accident of wearing; 2nd, the performance of 3D printed parts has not been high; a third problem is the presence of pores and unfutilized portions; and the fourth is that via a laser or electron beam as a heat source is quite costly.”
Experts have verified that parts created by 3D printing, casting and forging all-in-one technique are extra
stable than those created by traditional casting. Furtherextra
, the Chinese scientists say that the new technique is 80% extra
efficient than SLM 3D printing, with material costing around one-tenth that of metal additive building powders. The material utilized in the forging and casting technique is a kind of metal wire, that is heated by an energy-efficient electric arc that uses one-tenth the energy of a laser beam. This method, that can simultaneously control the dimensions and shape of performance parts, can reportedly save time as well as energy, with two-ton metal castings bringing just 10 days to create, previously three months.
The casting and forging process has may already been utilized to turn it into a titanium 3D printed joints for a new fighter aircraft, that may have been not easy to turn it into as a single piece via any subtractive building technique. In the past, the just method was to reduce the create standards, split it into multiple parts, and and so assemble it, affecting the performance of the fighter and shortening its life cycle. Zhang Haiou and his team have utilized their new technology to 3D print TC4 titanium alloy parts whose tensile durablity, yield durablity, ductility, and toughness are much advantageous than the traditional forging parts.
A number of experts, that include former Chinese Minister of National Aerospace Lin Zongtang, have suggested that the technology may showcase in the Made in China 2025 initiative, a national project inspired by Germany’s “Industry 4.0” scheme that can take on to “comprehensively upgrade Chinese industry.” The initiative can focus on promoting technology and equipment in aerospace, military and civilian planes, nuclear power applications, ships, high-speed rail and other key areas, so that the technology can improve the country’s building ability and defense durablity.

Posted in 3D Printing Technology

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