Supply chain drive lifts demand for new metal powders

A drive to maximise supply chain efficiency is accelerating development of metal powders for additive manufacturing for automotive, aerospace and other industrial applications.

Germany's EOS, which supplies technology for 3D printing of metals and polymers, has introduced eight new products, including processes for titanium-aluminium-vanadium (Ti-AI6-4V) alloys, a nickel-chromium alloy and an aluminium-silicon-magnesium alloy. Applications for the titanium alloys range from automotive and aerospace parts to other applications that require high strength and low weight. Nickel alloy can be used in injection moulding tools and inserts for mechanical engineering parts.

Lightweighting in transport is increasingly important as carbon emission reduction targets become tighter — reducing the weight of vehicles cuts engine emissions and increases the range of electric vehicles.

Customers are also increasingly seeking materials produced from sustainable feedstock as they move towards 'green' manufacturing and more efficient supply chains using domestic sources for powder production.

BMW has opened a €15mn additive manufacturing centre in Germany to bring together prototype and component production in one location, along with research and development. The company produced 300,000 parts with additive manufacturing last year.

It aims to develop new technologies to shorten production times and adopt more tool-less manufacturing, increasing automation. And the US' General Motors used 3D printing for 75pc of the components in its new Corvette model. The company plans to launch its Additive Industrialization Center in late 2020, having opened its Additive Innovation Lab last year.

In the aerospace sector, US-based QuesTek Innovations, which develops metal alloys and powders, has introduced a new stainless steel material for additive manufacturing that offers increased corrosion resistance and requires less heat treatment. Other applications include use in the defence, medical, chemical processing and energy sectors. QuesTek is also developing aluminium and titanium materials tailored for additive manufacturing.

UK-based ProtoLabs has launched a cobalt-chrome material for its direct metal laser sintering process, which has applications in aerospace engine manufacturing, the oil and gas industry and medical components. Its high strength-to-weight ratio and resistance to corrosion, heat and water meet the requirements of highly durable aerospace components, but make it difficult to manipulate the metal to produce parts. But 3D printing allows manufacturers to produce components in the exact shapes, geometries and weights required.

US-based metal powder producer 6K Additive is launching a plant to produce titanium and nickel superalloy powders. It has installed two production lines using its microwave plasma technology that can heat treat ferrous alloys, nickel superalloys, cobalt-based alloys, refractory metals — including molybdenum, tungsten and rhenium — and titanium-aluminium and aluminium alloys.

The facility will be able to produce 100 t/yr and will initially focus on nickel superalloys and titanium powders. In August, the company will begin sending customers samples of its Inconel 718 nickel-chromium alloy material, followed by its Ti-Al6-4V alloy. The plant will be able to convert machined millings, turnings and other recycled feedstocks into metal powders. The company plans to boost capacity in 2021 to meet rising demand.

By Nicole Willing