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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(lái)越復(fù)雜，通過(guò)傳統(tǒng)的注射成型方式已經(jīng)無(wú)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：?jiǎn)尉ф嚮辖饻u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(guó)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(mén)打開(kāi)系統(tǒng)支架，其作用是打開(kāi)和關(guān)閉發(fā)動(dòng)機(jī)的風(fēng)扇罩門(mén)，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(kāi)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(kāi)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(lái)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(guó)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(lái)一直在該工廠生產(chǎn)，標(biāo)志著規(guī)模化增材制造的重要里程碑，預(yù)計(jì)2019年這種產(chǎn)品將達(dá)到40000支。
 

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Application-specific products 1803-EEM03E4 EEM,24 ANALOG, 4 TO 20 MA, NEMA 4 ENCLOSURE

Operator Interface 2711-T10G15L1 PV1000 GRAYSCALE TOUCH, CNET & RS232 PRINT

Support 9301-2SE3500ZHR SUPT REINSTATEMENT CONTRACT FOR 93012SE3500ZH

Support 9381-PEDREPENS SUPT RENEWAL CONTRACT FOR 9381PEDREPEN

DeviceNet Products 1790D-T4T0 DNET LDX, 4 INPUT THERMOCOUPLE BSE, TERM BLOCK

RSI Software Products 9301-2SE330KOU2R RSVIEW32 RUNTIME 150-1500 UPGRADE OUT-SUPT (KO)

RSI Software Products 9358-PBNT60ENE RSBATCH NT FOR PROCESSLOGIX 60 UNITS

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

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

GQSM2D100L2P QUICKSTART KIT MINI GE LABEL

IC646NSL025 CIMPLICITY SQL - 25 Client License

MTR-5T66-H-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-2324 STXi output module 4 points, Positive Logic, 24VDC/ 0.5A

20BC085A3AYNACC1 PowerFlex 700 AC Drive 85 A 45 kW 20B

20F14NC104JA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A8P0N104 PowerFlex 4- 1.5 kW (2 HP) AC Drive

TSXMFPP001M Quantum Unity V2 PCMCIA存儲(chǔ)擴(kuò)展卡，程序存儲(chǔ)1x1024K（Flash）

284-PWRM22A-M1 ArmorConnect 3PH Pwr Media Shld Mtr Cbl

CJ1M-CPU12 CPU單元I/O點(diǎn)數(shù)320，10K程序容量，不可接擴(kuò)展機(jī)架。

1492-RCDA4C80 Residual Current Device 80 A

6ES7195-7HB00-0XA0 安裝兩個(gè) 40mm 寬的 I/O 模板，熱插拔

變送器 3RS11 42-1GW80

1497-K-HXDX-0-N Control Circuit Transber

1606-XLE480EP XLE Power Supply

1763-MM1 MicroLogix 1100 Memory Module

188-K3D320 Miniature Circuit Breaker 32 A

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