There are many die casting companies that provide additive manufacturing service. There are plenty of applications or uses for it in the aerospace industry. The segment is characterized by short runs of costly components, in which case additive manufacturing can lead to an overall lower cost, as opposed to that of pricey tooling for a traditional subtractive manufacturing process.
On the other hand, additive manufacturing techniques have been predominantly focused upon prototyping, which is done in order to boost research as well as development efficiency and to reduce the required time to deliver products to the market. Additive manufacturing, used as rapid prototyping, reduces the design validation as well as implementation process cycles and helps in releasing new versions of components quickly.
However, are there uses for it as a different manufacturing method? Can it allow product manufacturers out there to build functional parts in a cost-effective manner where traditional production techniques cost more in comparison? The answer to that seems to be a “yes”, especially when it lets manufacturers combine or integrate parts in one-step, like when complex inner channels, meshes and surface textures are comprised. Besides, additive manufacturing techniques can make an economic sense for high-value car parts that are also customized. An example is enhancing the efficiency of combustion and reducing the consumption of fuel using selective laser melting.
3D Printing Facts
Often, diesel engines of vehicles are turbocharged and after-cooled to improve their power capacity as well as fuel cutback. A turbocharger is considered an assembly of distinct parts and they are compressor housing, compressor, impeller housing, impeller, shaft, and a center gearbox housing.
A turbocharger is exposed to very high thermal as well as pressure stresses. Its center housing usually integrates internal channels supplying bearings using pressurized engine oil for the purpose of lubrication. Inner water-cooling passages are being designed to the housing in order to keep lubricant in a cool as well as liquid state. The housing is typically manufactured by the sand casting technique and then machined in order to form the inner cooling as well as lubrication channels. The design, engineering, as well as manufacturing considerations only go to show that producing the housing with an additive manufacturing process such as selective laser melting is most expected to contribute to the turbocharger’s efficiency as well as cost-effectiveness.
The process provides maximum design freedom for intricate and light rigid parts. Design engineers can develop intricate inner channels in the housing in order to enhance the cooling as well as lubrication system and that by extracting more heat.