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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：?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(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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2090-CSWM1DF-18AA03 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNAEG0 PowerFlex 70 AC Drive 20A

GC646MPSS50 Proficy GlobalCare Complete for Logic Developer - PLC Standard 50 Seat Site License

HE693RLY110 8 point, 8A Isolated Relay Module, 2 NO/NC, 6 NO

IC610CPU105RR Series One Plus CPU, 700 Words, Expandable to 1.7K Words

IC647HSTSC50KM Server to Server Collector for Historian - Standard Server 50000 Points (M4 Key)

IC660BBD020RR 24/48Vdc Source I/O Block, 16 Circuit, Ph B

IC694PWR321 Power Supply 120/240 VAC 125 VDC Standard

IC756WDN009E-27 DataViews Development System Visual Basic Java C++ & Native C English v2.7

MicroLogix 1500/1769 System 1769-RL1 REPLACEMENT DOOR LABELS FOR DISC. I/O (2 PER KIT)

PLC-5/1771 System 1771-P5E POWER SUPPLY, SLOT,8A,24V DC (EMI ENHANCED)

Distributed I/O 1798-IB8 FLEXARMOR 8 POINT 24 VDC SINKING INPUT MODULE

Operator Interface 2711P-B6M3D PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH485, DC PS

Support 9323-PA2JR SUPT REINSTATEMENT CONTRACT FOR 9323PA2J

Support 9358-PB10S SUPT RENEWAL CONTRACT FOR 9358PB10ENE

Support F1772-LZSERB FIRMWARE UPGRADE FOR 1772-LZ PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7FRE RSLOGIX 5000 FULL TO PRO UPGRADE, FRENCH

RSI Software Products 9305-RSVADFVCDEE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (GERMAN)

RSI Software Products 9301-PCI1500PFB APPLICOM PCI1500PFB PROFIBUS INTERFACE

Motion Control 2094-BM01 MODULE, AXIS, 400/460V, 9A INV.

A06B-0158-B075#7008 A40/2000 Servo Motor, Fan Package, 64K Serial Encoder

IC200UDR010 28 point; (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 24VDC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.