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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(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(zhǔn)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(fēng)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(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。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(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)計到生產(chǎn)于10個月內(nèi)開發(fā)完成。
在進(jìn)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(rèn)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(biāo)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(dá)到40000支。
 

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