3D printing process development and optimization: application to Binder Jetting and Direct Metal Laser Melting.

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Additive manufacturing (AM), also known as 3D printing, is gaining attention due to a substantial increase in the demand for high-performance materials with added functionalities, such as internal cooling channels or internal lattice structures, which are difficult to fabricate with conventional manufacturing processes, and increased complexities in geometrical design. Industries like transportation, aerospace and energy are aggressively pursuing new applications for AM. This CRD program aims to advance state-of-the-art technologies using AM of metals. More particularly, we seek to integrate new materials systems that pose different challenges to GE's two strategic technologies: Binder jetting (BJ) and direct metal laser melting (DMLM).BJ and DMLM are two complementary AM technologies. BJ is a cheaper and faster technology that allows the production of larger engineering parts, while DMLM is a more versatile technology capable of producing a wider spectrum of materials with better properties. The two technologies also complement each other in the type of materials they can produce. Brittle materials can be easily fabricated with BJ, while DMLM can be used to produce parts with materials that are hard to sinter. GE could leverage the two technologies with the large spectrum of engineering applications used in its different lines of business.GE Canada is taking an active part in the efforts to develop the next generation of aero engine. AM is required to produce new part designs that will enable a more efficient propulsion and reduce manufacturing costs. This project proposes to support GE Canada's efforts through two primary objectives: processing aluminum alloy (Al) powder using BJ to produce heat exchangers with a better heat dissipation capacity; seeking to build RENÉ65 superalloy with DMLM to produce the new 3D designed compressor vanes.Processing Al powder is challenging for manufacturing technologies because of its oxide film, which makes it difficult to sinter. We will innovate by using BJ to inject sintering agent on the surface of Al powder through fine nozzles, which should disrupt the oxide film chemically and allowing sintering to occur.High ?' superalloys, like RENÉ65, are hard to produce using DMLM due to their high cracking susceptibility, residual stress build-up, and poor understanding of the processing-microstructure. The second objective will focus on developing know-how to build RENÉ65 thin-wall components with DMLM. This research project will help GE's Canadian plants to instigate new AM technologies. GE Bromont and GE Additive in Saint-Eustache, for example, could act as technology receptors. Additional benefits to Canada come from the technology transfer of this research to numerous aerospace, automotive, and materials companies. AM technology will facilitate the customized production of strong lightweight products, allow designs that were not possible with previous manufacturing techniques, and reduce costs associated with assembled components.