aerospace

Breaking boundaries 3D Printing method for Steel-Aluminum fusion.

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Steel and aluminum, stalwarts in economic growth, have long been rivals in various industries. The challenge, however, has been joining them seamlessly due to the brittleness in their fusion zones. Explore the groundbreaking 3D printing method that may pave the way for a steel-aluminum hybrid renaissance, transforming industries like automotive, aerospace, and critical infrastructure. In the world of automobiles, steel boasts strength and cost-effectiveness, while aluminum offers a superior strength-to-weight ratio. Combining these metals could revolutionize weight-saving designs, crucial for reducing carbon emissions. Yet, the formation of a brittle intermetallic compound (IMC) at their juncture has impeded exploration of this alloy.

Research co-lead Motomichi Yamamoto and the team from Hiroshima University’s Graduate School of Advanced Science and Engineering present a 3D printing method that conquers the challenge. By employing a combination of the hot wire technique, diode laser, and fluxes, they effectively control the thickness of the IMC in joint zones of stainless steel and aluminum alloy. Presenting their findings at a prestigious welding conference, the researchers detail the intricate process. Through the hot wire method, aluminum alloy is heated close to its melting point before being deposited into a molten pool, where dissimilar metals merge. Flux application methods, laser spot sizes, and process speeds are meticulously tested to optimize bead formation and minimize IMC formation. The optimized calibrations result in stainless steel and aluminum bonds withstanding impressive separation stress. With tensile strength tests reaching up to 17,404.5 pounds per square inch, the method showcases its potential for high-strength direct joining.

This innovative 3D printing method not only addresses the brittleness challenge but also opens doors to innovative product designs. Join us in exploring the transformative implications of this groundbreaking approach, potentially reshaping the future of material fusion in various industries.

By Hiroshima University. The new 3D printing method creates a steel-aluminum fusion hybrid.

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Valiant products take off with Velo3D Sapphire XC joining the contract manufacturing network for 3D Printing rocket engine parts.

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Valiant Products is embarking on an exciting journey in additive manufacturing, leveraging the advanced capabilities of Velo3D’s Sapphire XC system. The company, renowned for its commitment to innovation and pushing the boundaries of manufacturing technology, has announced its plans to 3D print rocket engine parts using the cutting-edge XC metal machine. While Valiant has expressed its intention to upgrade to the Sapphire XC 1MZ in the future, the immediate focus is on utilizing the XC system to produce high-quality parts for rocket engines. This strategic decision was influenced by a mutual customer who recognized the potential of Velo3D’s metal additive manufacturing technology in enhancing their supply chain.

The Sapphire XC system at Valiant Products has been meticulously calibrated to process Inconel 718, a material known for its high strength and corrosion resistance. Widely utilized in mission-critical applications in the aerospace industry, Inconel 718 aligns with Valiant’s commitment to providing top-notch solutions for its customers. Bob English, Founder, and CEO of Valiant Products, highlighted the company’s dedication to exploring new manufacturing technologies to offer customers access to the best capabilities for producing complex designs and geometries. He expressed confidence that Velo3D’s metal 3D printing technology will empower customers to build lighter-weight and more performant parts. Michelle Sidwell, Velo3D EVP of Global Sales and Business Development, commended Valiant Products for its innovative approach to addressing customer challenges. The installation of the Sapphire XC at Valiant has showcased their meticulous attention to detail. With its proximity to the Cape Canaveral launch pads, Valiant is positioned to be a valuable resource for aerospace customers seeking to manufacture parts for rocket and air-breathing engines.

As Valiant Products joins Velo3D’s contract manufacturer network, the collaboration promises to transform aerospace supply chains. The fully integrated solution, coupled with the expertise of both companies, is set to bring about a significant impact on the way rocket engine parts are manufactured. The aerospace industry can anticipate a new era of lighter, more efficient components, thanks to the strategic partnership between Valiant Products and Velo3D.

By 14 November 2023, 15:20.

Valiant Products to 3D print rocket engine parts with Velo3D Sapphire XC system.

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