Cummins partners with ORNL on repairs using metal Additive Manufacturing

September 22, 2017

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.”

September 22, 2017

In the latest issue of Metal AM magazine

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Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

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  • General Atomics Aeronautical on metal Additive Manufacturing’s place at the centre of the digital manufacturing revolution
  • Adrian Keppler on Additive Manufacturing: An insider’s assessment from the outside
  • Metal AM’s journey to industrialisation: Are we there yet? And what does the destination even look like?
  • A stronger future, layer by layer: How next-generation software will drive adoption of metal AM
  • Volkmann: Making the case for the complete automation of powder handling in AM
  • Metal AM on an industrial scale: GKN Additive draws on decades of sintering expertise to commercialise Binder Jetting
  • International Conference on Electron Beam Additive Manufacturing: Highlights from EBAM 2023

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