GE engineers switched four existing parts from castings to metal 3D printing and see potential for hundreds more as AM competes with casting on cost alone.

Most manufacturers would never dream of switching an existing part from an investment casting to one made by metal AM.  But that is exactly what GE Aviation engineers are doing with four bleed air parts for a turbine engine. The decision was based on cost and time-to-market, even though the casting molds were already made.

This Self-Study Course provides a broad introduction to the fundamental principles of powder metallurgy. The user will gain an understanding of basic science and engineering as it relates to the technology. Practical applications of metal and alloy behavior, various manufacturing processes, and management objectives will be explored. This technically in-depth Course provides valuable knowledge for career development.

This Course contains 30 pre-recorded videos that average 60 minutes each. The Course will be open to the student for 6 months from the date of purchase.

The Binder Jet Metal AM process at Cummins. Photo via Cummins Inc.

Founded in 1919, Cummins Inc., Columbus, IN, has designed, manufactured, and distributed a broad portfolio of diesel, natural gas, electric, and hybrid powertrains. They also produce related components for filtration, fuel systems, turbochargers, automated transmissions, batteries, and fuel cells. Now they can add metal additive manufacturing (AM) to their portfolio as they are in the process of final approval for its first metal AM production part.

The part is a Cummins Emission Solutions (CES) lance tip adapter, a critical part that atomizes and injects diesel exhaust fluid into a high-horsepower engine, reducing nitrogen oxides emissions. Production is slated for later this year. Producing the lance tip adaptor through binder jet AM provided several benefits over traditional manufacturing techniques, such as a lighter-weight design, improved geometry for fluid and air flow, and removed the added complexity of cross-drillings.
 

Innovation is often the direct result of a commitment to find better ways to solve existing problems. And having an interest in finding ways to leverage metal AM is nothing new to Ford Motor Co. The global automaker has been a long-time user and an early adopter of 3D printing. Advancing from simple prototypes to applications now limited low-volume production parts are utilized in the F-150 Raptor and Shelby GT500 Mustang.

North American and European facilities are supplying tens of thousands of parts per year. Ford is expanding AM into its manufacturing facilities to support and enhance production processes too.  Internal education has been launched within the workforce to advance the understanding of the technology and open opportunities to expand to more complex, higher volume and more physically demanding applications.  The result is nearly one printer in every Ford facility throughout the world, and in many cases, multiple printers.   
 

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