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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，為了形成高度復雜的內(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)越來越復雜，通過傳統(tǒng)的注射成型方式已經(jīng)無法實現(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。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)動機支架
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3D打印支架用于波音747-8 機型的GEnx-2B發(fā)動機（雙轉(zhuǎn)子軸流式大涵道渦輪風扇發(fā)動機），該支架將取代傳統(tǒng)制造的電動門打開系統(tǒng)支架，其作用是打開和關(guān)閉發(fā)動機的風扇罩門，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90%的材料浪費。在傳統(tǒng)支架的制造中，因金屬加工而產(chǎn)生的材料浪費約占50%。此外，3D打印支架采用了優(yōu)化設(shè)計方案，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“第一”。首先，這是GE 第一個獲得認證的由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)計到生產(chǎn)于10個月內(nèi)開發(fā)完成。
在進行支架生產(chǎn)時，一次打印可以生產(chǎn)4個支架，在構(gòu)建室中4個支架以互鎖設(shè)計的形式實現(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)動機的訂單量為2200臺，整體來看節(jié)約的成本非?？捎^，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)動機作為A320neo飛機的選配，LEAP發(fā)動機中就帶有3D打印的燃油噴嘴。2015年5月19日，A320neo飛機首飛成功，裝有LEAP發(fā)動機的A320neo 同時獲得歐洲航空安全局和美國聯(lián)邦航空管理局的認證。
2018年10月8日，GE航空工廠慶祝第30000個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)，標志著規(guī)模化增材制造的重要里程碑，預(yù)計2019年這種產(chǎn)品將達到40000支。
 

GC646VPN999 Proficy GlobalCare Complete for VersaPro Nano/Micro Edition - Site License

IC200ALG262 Analog b 15 bit current differential 8 channel

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Distributed I/O 1798-OB8E FLEXARMOR 8 POINT 24VDC SOURCING OUTPUT MODULE

Operator Interface 2711P-B6M5D PV PLUS 600 GRAYSCALE, KEY/TOUCH, RS232, DC PS

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MTR-1N41-G-E-A-E-0RR Stepping Motor Nema42

ZA06B-0128-B575#7076 A6/3000 servo motor with IP67 sealing and 64k serial encoder

20BD5P0A3AYNACC0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14GD125AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D6P0 PowerFlex 520 2.2kW (3Hp) Power Module

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150-SD3NBR SMC-50 SOLID STATE MOTOR CONTROLLER 520A

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193-KA25 0.16-.25 A IEC Bibllic Overload Relay

20-750-NEMA1-F7 PowerFlex 750 Frame 7 Conduit Box Kit

2090-CPWM7DF-16AF15 MP-Series 15m Length Power Cable

20AB022C3AYNANC0 PowerFlex 70 AC Drive 22 A at 7.5 Hp 20A

GA647IFPLDV00075 GCA iFIX Plus SCADA 75 I/O Dev

GP647IFCLNTCRN GCP iFIX iClient Run

IC600BF810RR 115V Isolated Input Module (6 points)

IC647HSTCC300M Calculation Collector for Historian - Standard Server 300 Points (M4 Key)

IC647TBLCPVC050 Virtual Campus for Proficy Troubleshooter and Cause+ - 50 Users

IC693MDL916 Output module, Isolated Relay, Normally Open, 4 Amp, 16 point. Requires High Density Terminal Block (IC694TBBx32 or IC694TBSx32). Compatible with RX3i and Series 90-30.

IC756LDV001E-97 DV Development - Inb/Linux RedHat Addt'l User, English, Version 9.7

Pico Controllers 1760-CBL-INT05 PICO-LINK CONNECTIVITY CBL 1.5M 1 PCS/PACK

PLC-5/1771 System 1771-OG TTL OUTPUT MODULE

Distributed I/O 1791-16B0 BLOCK I/O, 24V DC, 16 POINT MODULE (16 INPUT)

Communications 1786-TNCJ4 CONTROLNET TNC COAXIAL CONN - JACK TO JACK

Operator Interface 2707-MVH232 MICROVIEW, HAND-HELD, 2 LINE LCD, RS-232

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EtherNet/IP Products 1734-AENT 24V DC ETHERNET ADAPTER

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4363-H 4363 WITH 0-10 V OR 4-20 mA OUTPUT

IC200ACC415 RS-232 to RS-485 Converter requires IC200CBL500 or equivalent.

IC693MCM001 Series 90-30 Digital Servo Interface Module

TRM-21000422 Screw Terminal Connector 14 Pt. Obsolete Whedco PowerCube Replacement Only

VMEM-ADM VisualMEM Admin Seat

20BD022A0AYNANA0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FC030AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D012N103 PowerFlex 400- 5.5 kW (7.5 HP) AC Drive

140CRA93200 Quantum RIO 站適配器, S908 RIO, 單電纜，遠程（分站）

285-BRC25-M14D Source Brake Patchcord Cable, 14M, M25

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150-C60NBD SMC-3 60A Smart Motor Controller

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1771-ID16 Isolated Input Module, 120VAC

193-EC3DD E3 Plus 9-45 A Overload Relay

198-MT4 ModCenter IEC Selector Switch

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GFK-0631 Series 90-30 I/O Link Slave Interface User's Manual

IC200UEX824 VersaMax Micro 4 channel Thermocouple/mV b expansion module. Supports Type K,J,E,S,T,B,N,-/+50mV,-/+100mV bs, 12bit resolution. Power source required for expansion module is 24VDC.

IC647AQC025 PA Quality Client 25 Pak

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IC693CMM301RR Genius Communications Module, GCM (256 bits)

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MMR-B00P-1M-0 Target series motion controller 1 MB battery backed RAM memory card

SLC/1746 System 1747-OS302 SLC 5/03 UPGRADE KIT

Distributed I/O 1734-IA2 120 VAC 2 CHANNEL INPUT MODULE

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Motion Control MPL-B660F-SJ22AA MOTOR,SERVO,48.0NM,3000RPM,SINGL,460V

Miscellaneous CRIO-PS241 I/OPOWRSUPL(24VDC)WERSUPL

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194L-HE4A-875 IEC Control And Load Sw Actuator Type A

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IC646PPA364 PA-30 with 364 CPU - AC

IC647NAC003 CIMPLICITY Alarm Cast Enterprise Version

IC687RCM711 Half Slot Redundant Communications Module for HSB Systems

IC697VDD100 Discontinued. Replacement is Embedded VME-1182A-020000. Contact GE Embedded for more details.

IC800SSI420RD2RR 20A, 480V, DeviceNet S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-BSN BACKUP SCANNER MODULE

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Support 9393-RSTLX5KR SUPT REINSTATEMENT CONTRACT FOR 9393RSTLX5K, PLX5K

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IC800SSI104RS1 4.3A, 115/230V, S2K Servo Controller for MTR Series Motors

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20DE011A0EYNANANE PowerFlex 700S AC Drive 20D

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2711P-K12C4D9 PanelView Plus Terminal

280-PWRM35D-M12 ArmorStart Three-Phase Power Media

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194E-KA20E-P11 194E Load switch

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2090-UXNBMP-18S01 MP-Series 1 m Length Brake Cable

BC646SPD365M Solution Provider Batch Key (M4)

GC647IFCLNTSRO050 GCC iFIX iClientTS Read Only 100 PK Runtime Version

IC200ALG327 Analog output 13 bit voltage 12 channel

IC646MBS001 Machine Edition Standard Development Suite

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IC660SLD020 Red Safety Label Kit for IC660BBD020 Genius Blocks

IC697CGR935RR Hot Standby Genius Dual Bus CPU, 486DX4, 12K Discrete I/O, I M fixed u ser memory, Floating pt.

IC800CBL061 Power cable for A6/3000 motor. 14 meters

ControlLogix/1756 System 1756-M24 LOGIX5555 3.5MBYTE NONVOLATILE MEMORY

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IC300TRM012 Spring-clamp style I/O plug, 12-terminal

IC800APK130 130 Amp Alpha Series Amplifier Package

MTR-3T69-G-R-0-M-0RR Servo Motor Metric

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20DC056A0EYNANANE PowerFlex 700S AC Drive 56 A 30 kW 20D

20G1ANC456JA0NNNNN PowerFlex 755 AC Packaged Drive

25C-B032N104 PowerFlex 527 7.5kW (10Hp) AC Drive

280-MTR22-M3 ArmorStart 90 Degree M22 Motor Cordset

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GC646MRB159 Proficy GlobalCare Complete for Logic PC Runtime 1,500 I/O

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IC647HSTSS15KM Historian Standard Server 15000 Points (M4 Key)

IC660BBD120 Block High Speed Counter

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A06B-6093-H101 Beta Series SVU-12 12 Amp Amplifier

IC200UEX210 28 point expansion. (16) 120VAC In, (12) 120VAC Out, 120/240VAC Power Supply. (Includes IC200CBL501)

IC752CKT014 DATAPANEL 150 STARTER KIT

MTR-3N31-H-R-0-N-SRR Servo Motor Nema34 with Seal

ZA06B-0153-B075#7008 A30/3000 servo motor with 64k serial encoder

20BD8P0A0AYNAND0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14NC260JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-V4P8 PowerFlex 520 0.75kW (1Hp) Power Module

OFSCSPEST Quantum 10 LIC. OFS SMALL Expired Subbion

FVR 1. 5E11S-7JE 3. 0KVA 8.0A 1.5KW 單相AC220V/50Hz/60Hz

1492-J3P 2.5 square mm Standard Terminal Block

1492-SPM3D150 MCB Supplementary Protector 15 A

軟啟動器 3RW40381BB04

SIMATIC HMI 系列面板 6AV2124-1MC01-0AX0 KP1200 精智 12 英寸，按鍵

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1738-IB8M12 ArmorPoint 8 Point Input Module