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3D打印在航空制造中的應(yīng)用
1、打印渦輪葉片鑄造型芯
在鑄造金屬渦輪葉片時(shí)，為了形成高度復(fù)雜的內(nèi)部冷卻通道結(jié)構(gòu)，常使用陶瓷鑄造型芯。鑄造葉片冷卻后，將葉片從模具中取出，同時(shí)內(nèi)部的陶瓷型芯需要溶解掉。
目前，陶瓷鑄造型芯的結(jié)構(gòu)越來越復(fù)雜，通過傳統(tǒng)的注射成型方式已經(jīng)無法實(shí)現(xiàn)。奧地利Lithoz公司采用LCM技術(shù)制造陶瓷葉片型芯，可以滿足航空航天和電力工業(yè)的需求。
LithaCore 450是由Lithoz公司自主研發(fā)用于3D打印陶瓷葉片型芯的硅基材料，制備精度高，燒結(jié)后的葉片型芯產(chǎn)品具有非常低的熱膨脹率、較高的孔隙率、優(yōu)異的表面質(zhì)量和優(yōu)良的洗濾性等優(yōu)點(diǎn)。典型的應(yīng)用有：單晶鎳基合金渦輪葉片鑄造型芯、定向凝固鑄造型芯、等軸鑄造型芯。
2、打印發(fā)動(dòng)機(jī)支架
2018年11月1日，GE增材制造宣布，美國聯(lián)邦航空管理局已批準(zhǔn)3D打印支架用于波音747-8 機(jī)型的GEnx-2B發(fā)動(dòng)機(jī)（雙轉(zhuǎn)子軸流式大涵道渦輪風(fēng)扇發(fā)動(dòng)機(jī)），該支架將取代傳統(tǒng)制造的電動(dòng)門打開系統(tǒng)支架，其作用是打開和關(guān)閉發(fā)動(dòng)機(jī)的風(fēng)扇罩門，制造設(shè)備為GEAdditive Concept Laser M2多激光器選區(qū)激光熔融系統(tǒng)。



這款3D打印支架將在GE航空集團(tuán)阿拉巴馬州奧本市的工廠開始批量生產(chǎn)。GE公司表示，與傳統(tǒng)方式制造的支架相比，3D打印技術(shù)將減少高達(dá)90%的材料浪費(fèi)。在傳統(tǒng)支架的制造中，因金屬加工而產(chǎn)生的材料浪費(fèi)約占50%。此外，3D打印支架采用了優(yōu)化設(shè)計(jì)方案，重量比傳統(tǒng)支架輕10%。


據(jù)了解，這款3D打印支架為GE航空創(chuàng)造了兩個(gè)“第一”。首先，這是GE 第一個(gè)獲得認(rèn)證的由ConceptLaser公司的選區(qū)激光熔融設(shè)備生產(chǎn)的3D打印零件。其次，這是GE航空第一次完成一種3D打印零件從設(shè)計(jì)到生產(chǎn)于10個(gè)月內(nèi)開發(fā)完成。
在進(jìn)行支架生產(chǎn)時(shí)，一次打印可以生產(chǎn)4個(gè)支架，在構(gòu)建室中4個(gè)支架以互鎖設(shè)計(jì)的形式實(shí)現(xiàn)，打印材料為鈷鉻合金。
3D打印支架的制造成本低于原有成本，GEnx發(fā)動(dòng)機(jī)的訂單量為2200臺(tái)，整體來看節(jié)約的成本非常可觀，并且3D打印支架比傳統(tǒng)支架更輕，將為航空公司節(jié)省燃料。
3、打印燃料噴嘴
2010年，空客將GE生產(chǎn)的LEAP-1A發(fā)動(dòng)機(jī)作為A320neo飛機(jī)的選配，LEAP發(fā)動(dòng)機(jī)中就帶有3D打印的燃油噴嘴。2015年5月19日，A320neo飛機(jī)首飛成功，裝有LEAP發(fā)動(dòng)機(jī)的A320neo 同時(shí)獲得歐洲航空安全局和美國聯(lián)邦航空管理局的認(rèn)證。
2018年10月8日，GE航空工廠慶祝第30000個(gè)3D打印燃料噴嘴的成功出貨。該噴嘴自2018年以來一直在該工廠生產(chǎn)，標(biāo)志著規(guī)?；霾闹圃斓闹匾锍瘫?，預(yù)計(jì)2019年這種產(chǎn)品將達(dá)到40000支。
 

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Motion Control MPL-A330P-HJ24AA MOTOR,SERVO,4.18NM,5000RPM,ENCR,230V,BRK,6.1KG

Motion Control 2090-UXBC-D1509 BREAKOUT BOARD CABLE,CN2,ULTRAX000,9M

CBL-12-MPS-10 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 10 Ft.

IC600KD542RR Operator Interface Terminal, 14" Color CRT

IC800SKCBV100 Power/Brake Cable, S2K to 1 - 2.5kW S-Series Servo Motors, 10 Meters

OC647IFESGRN00900M iFIX Optn: ESig & ERec 900 I/O Runtime (M4 Part)

20AD052A0AYNANC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A0EYNANANE PowerFlex 700S AC Drive 20D

20LD650N0QNNENA0EA PowerFlex 700L AC Drive 20L

2707-NC9 MICROVIEW-MLOGIX COM CBL 49 FT/15 M.

280-PWRM22E-M14 ArmorConnect 3-PH Power Media drop cable

FX2N-422-BD RS422 通信用適配器

1492-M6X5H1-50 Connection Products

1494R-N4 Disconnect Switch Shaft

軟啟動(dòng)器 3RW44476BC46

ET 200SP 6ES5710-8MA31 35mm安裝導(dǎo)軌，長度：830mm

1585D-M4UBDE-2 Micro D-Code, QD Style Ethernet Media

1756-IB16IFK ControlLogix 16 Point Digital Input

1794-TB3SK Flex Terminal Base

194E-E100-TN Neutral Terminal 80 - 100 Amp

2090-CFBM4DD-CDAA15 MP-Series 15 m Length Feedback Cable

2090-K7CK-KENDAT Kinetix 7000 EnDat Converter Module

AT-8624FC-10 Proficy Process Systems Switch with no Multi-mode Fiber Modules from Allied-Telesis

GC646TDV300 Proficy GlobalCare Complete for 300 I/O Point Runtime / Development System.

HMI-AGO-201 ANTI-GLARE OVERLAY 9 inch/ 5 per pack

IC640WDB400 Cable, 9-Pin D to 3 BNC

IC647HSTSSEO50KM eSignature Option for Historian - Standard Server 50000 Points (M4 Key)

IC660BSM021RR Bus Switching Module, 115 Vac/125 Vdc

IC695DEM004 Beta i Series 1-Axis Motion Demo Case for use with PACMotion or DSM324i motion controllers