HBD reports breakthrough in turbine blade production with 96% support reduction
Chinese metal Additive Manufacturing machine maker Shanghai Hanbang 3D Tech Co, Ltd (HBD) has reported a breakthrough in the Additive Manufacturing of turbine blades. In a recent study, the company was abile to decrease the unsupported angles in the impeller from the conventional 45° to just 6°, leading to a 96% reduction in overall support volume.
“Throughout the turbine blade printing process, we eliminated the internal support structures of the specimen impeller, employing only a minimal amount of support structures designed for easy removal,” the company stated. “This substantially alleviated the challenges associated with support structure removal and significantly reduced the time required for the process.”
HBD explained that the addition of appropriate support structures ensures the stability of manufactured parts, especially in preventing deformation from thermal stresses, facilitating heat transfer away from the melted material, and shielding the forming part from the recoater blade, which could potentially disrupt the part’s shape upon impact. Moreover, they assist in attaching the part during the build process to maintain stability.
However, most metal Additive Manufacturing machines limit the angle of unsupported overhanging features to approximately 35-45°, HBD added. As each additional support structure prolongs manufacturing time, increases material costs, and requires removal through time consuming post-processing, productivity decreases.
To reduce the number of support structures in Additive Manufacturing, HBD had to make several technological advancements. This included the optimisation of algorithms for the support structures, real-time control of melt pool temperature, optimisation of powder deposition, and the development of metal alloy materials tailored for unsupported Additive Manufacturing.
While achieving 100% unsupported Additive Manufacturing remains a challenge, key industry players have reportedly initiated research into unsupported/less supported manufacturing technology. HBD said it is committed to further exploring unsupported/less supported manufacturing technology, with the aim of providing clients with more efficient and reliable metal Additive Manufacturing solutions and expanding the possibilities for industrial manufacturing.
