Replacement Parts

Load-bearing, metal 3D printed A-Hyperlink spare section authorized by EASA

Stay up to date with all the things that is taking place in the great environment of AM via our LinkedIn community.

In their joint effort and hard work to use additive manufacturing strategies for a much more cost-economical aircraft spare areas manufacturing, Lufthansa Technik and High quality AEROTEC recently arrived at an vital milestone: A metallic ingredient made at Lufthansa Technik’s Additive Producing (AM) Centre for the IAE-V2500 engine’s anti-icing process has now obtained its official aviation certification from EASA. On this foundation, Premium AEROTEC will make the so-called A-Connection for Lufthansa Technik at its Varel (Germany) site utilizing a 3D printer.

Premium AEROTEC is a pioneer in the implementation of AM in the aerospace segment. Again in 2017, the organization disclosed in an exclusive interview with 3dpbm that it was performing on the closing qualification for a set of sections for Airbus’ A350 plan. In 2015 Premium AEROTEC opened a producing facility focused totally to AM. And in 2016, the enterprise obtained acceptance from the EASA to additively manufacture titanium pieces for serial production of its A400M military plane.

A complete of 9 of these A-Links resolve a ring-shaped very hot air duct in the engine’s inlet cowl, which is consequently secured from ice buildup all through flight functions. Having said that, the vibrations that come about listed here for the duration of operation trigger the A-inbound links to put on at their mounting holes, so that after a few years they are typically ripe for substitution.

As the A-Backlinks can be uncovered to temperatures of up to 300 degrees Celsius, they are designed of titanium. In the unique, the element is manufactured by a forging process to satisfy the best demands for content properties. The new manufacturing remedy formulated by High quality AEROTEC and Lufthansa Technik, having said that, is designed layer by layer via Laser Powder Bed Fusion (LPBF). This offers the benefit about forging that no jigs or molds are necessary for output. In addition, the process can conserve precious material, since following 3D printing a material elimination is only vital to a pretty tiny extent on some functional surfaces.

Load-bearing, metal 3D printed A-Hyperlink spare section authorized by EASA

Nevertheless, the homes of the components created in this way, for instance, their power, are seriously dependent on the corresponding additive manufacturing method, the qualification of which have to as a result be confirmed in a intricate treatment. To this conclusion, Premium AEROTEC carried out a huge quantity of print positions with test specimens, with regular settings of all method-related parameters. This way, it was lastly attainable to establish a regular and trusted system and to confirm that the best prerequisites in phrases of materials properties are also realized listed here. In terms of tensile strength, the additively made A-Website link is even top-quality to the original element.

As component of this certification process, Lufthansa Technik has now prolonged the expertise of its EASA Component 21/J improvement facility to contain additively produced steel factors. For Top quality AEROTEC, the cooperation with Lufthansa Technik is a significant milestone in the industry of additive producing, as it is the very first time the firm has provided a consumer outside the house the Airbus Team with printed collection factors. The initial A-Inbound links from the cooperation will be utilised in the Lufthansa fleet, in which very long-phrase encounter with the new parts is to be received beyond certification.

“Premium AEROTEC is an worldwide pioneer and technology chief in the additive manufacturing of aerospace components. Our company has by now been applying this engineering in the collection output of elaborate structural factors because 2016,” reported Dr. Ulrich Weber, Chief Running Officer at Quality AEROTEC. “I am really happy that in cooperation with Lufthansa Technik we can now after again demonstrate our detailed expertise in 3D printing.”

Lufthansa Technik and Premium AEROTEC reach key milestone in AM with load-bearing, metal 3D printed A-Link spare part approved by EASA

“We have been creating components for the plane cabin, the large greater part of which are created of plastic, utilizing 3D printing for many years. Now we are in a position to exhibit that structurally related metallic pieces for use outside the cabin can also be produced additively and accredited for flight operations,” said Soeren Stark, Main Operating Officer of Lufthansa Technik. “In this way, we have not only obtained a price tag-saving for the ingredient in concern but also defined and experienced all the important procedures for the software of this groundbreaking producing approach for structurally appropriate metallic areas.”

Even so, the 1st aviation certification of a load-bearing steel spare section presently represents only a initially stage for equally partners, as its geometry continue to mostly corresponds to the primary section. Future developments in the technology will also make it possible to use the pros of additive producing for targeted optimization of geometry. Theoretically, there are no limits to the shaping of additively manufactured elements, so that they can then be created a great deal a lot more effortlessly and with fewer product though retaining the exact same energy and function. Both equally associates intend to further establish these alternatives in the close to long run.

Related Articles

Back to top button