Cummins partners with ORNL on repairs using metal Additive Manufacturing

September 22, 2017

Cummins partners with ORNL on metal 3D printed repairs

Cummins diesel engines are used in many heavy-duty truck makes globally (Courtesy ORNL)


Diesel engine maker Cummins, Inc., Columbus, Indiana, USA, is collaborating with Oak Ridge National Laboratory, Oak Ridge, Tennessee, USA, to develop a method and material to repair the cylinder heads on heavy-duty engines by Additive Manufacturing.

Cummins diesel engines are used in many heavy-duty truck makes globally. According to the manufacturer, the cylinder heads on these engines typically wear out after a million miles on the road. Ordinarily, these cast iron parts would have to be replaced with new castings; a costly process in terms of time, energy and money.

Using the new method of repair, the research team ‘scoops out’ the worn section and uses a Direct Metal Deposition (DMD®) machine by DM3D Technology, Auburn Hills, Michigan, USA, to deposit a high-nickel-containing alloy over the damaged area. This material offers a number of properties which help to avoid cracking of the repaired cylinder head and increase its thermal efficiency

The goal of the new repair process is to save energy at the same time as extending the life and increasing the strength of the engine. “We’re decreasing the engine’s thermal conductivity, which holds heat in longer, and turning it into increased efficiency,” explains Nikhil Doiphode, Parts R&D Engineer at Cummins. “While these are not brand-new engines, we’re striving to make them better than new.”

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As well as an extensive AM industry news section, this 188-page issue includes articles and reports on:

  • From rapid prototyping to rocket engines: The evolution of 3T Additive Manufacturing
  • Natural resources and national strategies: How metal Additive Manufacturing is taking off in Australia
  • Scalmalloy® is too expensive and design optimisation only makes sense in aerospace. True or false?
  • Safety management in metal Additive Manufacturing: Observations from industry
  • Senvol: How machine learning is helping the U.S. Navy optimise AM process parameters and material performance
  • Understanding build failures in Laser Powder Bed Fusion: An overview
  • MAMC2018: Vienna hosts ASMET’s third Metal Additive Manufacturing Conference
  • Euro PM2018: The processing and properties of additively manufactured aluminium alloys
  • > More information

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