Additive manufacturing 3D-printed aftermarket part solutions for gas turbines in aviation and energy

Editor: Alexander Stark

USA — Chromalloy, a manufacturing and repair solutions provider for gas turbine engine manufacturers and operators worldwide, recently selected the Velo3D Sapphire system as their additive manufacturing (AM) solution. The customer hopes to significantly impact the economics of future Maintenance, Repair & Operations (MRO) projects in their aviation and energy markets.

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Additive manufacturing promises to keep aging engines operational with greater flexibility and shorter delivery times than traditional MRO supply chains.
Additive manufacturing promises to keep aging engines operational with greater flexibility and shorter delivery times than traditional MRO supply chains.
(Source: Public Domain / Pixabay )

The US company Chromalloy is installing the VElo3D Sapphire AM solution in its manufacturing and repair services environment. This industrial AM technology is increasingly being adopted by manufacturers as a solution to offset the high costs of low-volume, direct-part replacement for conventionally produced parts when demand and long-term forecasting are uncertain.

According to Chromalloy’s Jim Whitton, Director, Innovation Strategy, 3D printed parts must provide inherent value because they are 3D printed. Otherwise, the printing itself was just a novelty. Velo3D’s unique build capability and material density created high value by reducing post-processing requirements, he states.

The AM company will qualify Chromalloy’s machine for 3D printing nickel-based superalloys, including Hastelloy X, which is known for its strength and durability characteristics in high temperature environments. Geometric freedom is guaranteed by a patented Support Free process. The capability to produce practically unlimited geometries eliminates the need to redesign legacy parts in order to produce them with AM. This tremendously reduces the barrier of transitioning legacy parts, produced historically by casting, welding or brazing, to additive manufacturing.

All Sapphire machines come standard with Velo3D ‘s highly automated, user-friendly Flow pre-print software and Assure quality assurance and control system.

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