Renishaw and Metalpine develop copper-nickel alloy powders for marine applications
April 29, 2025
Renishaw, headquartered in Wotton-under-Edge, Gloucestershire, UK, has collaborated with Metalpine, based in Graz, Austria, to create copper-nickel alloy (CuNi) powders for use in marine applications. It was stated that a major European naval force is set to use the new powder to manufacture replacement parts in-house using Renishaw’s RenAM 500Q Flex Additive Manufacturing machine.
Naval operations in saltwater environments present challenges, with hydraulic components and other essential parts subject to accelerated wear and corrosion. Rather than relying on extensive supply chains, the naval force opted to additively manufacture replacement parts in-house.
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CuNi powders form a protective layer on the surface of components, preventing degradation. This makes them highly durable in the challenging marine conditions where parts are constantly exposed to moisture and sea elements. Engineers from Renishaw and Metalpine partnered to develop process parameters tailored to two specific copper-nickel alloys: CuNi 10, a combination of 10% nickel and 90% copper, and CuNi 30, using 30% nickel and 70% copper.
“Metalpine uses a stable and outstandingly efficient process to manufacture high-quality metal powders focused on particles with high sphericity and no pores. So, it is straightforward for us to develop and produce new powders,” Gerald Pöllmann, CEO of Metalpine, shared. “Collaborating with the AM engineers at Renishaw was a great experience. The team quickly shared what they achieved with our powders during their qualification process, enabling us to create and deliver powders that fit the application perfectly.”
With an open-loop powder system, the RenAM 500Q Flex allows for efficient and quick powder swapping, making it ideal for developing and optimising material properties, part designs and process parameters. With the Reduced Build Volume (RBV) accessory fitted, material prove out can be performed with as little as 0.25 litres of powder, with the same processing environment and optics as the full-scale production system.
“Metal powders made with copper are difficult to process with AM. CuNi 10 is a highly reflective material which is resistant to laser energy, whereas CuNi 30, due to its higher nickel content, is easier to process,” explained Alex Garcia, AM Design and Applications Engineer at Renishaw. “Leveraging Renishaw’s advanced laser melting technology, we conducted extensive experimentation to refine the energy input parameters. We adjusted the RenAM 500Q Flex power, scan speed and hatch distance to optimise the process for manufacturing with these materials.”
“With these precise settings, we have been able to overcome the material’s challenges, ensuring high-quality, durable parts that can withstand harsh marine environments. This optimisation not only enhances part strength and longevity but also ensures consistent results, allowing our naval customer to manufacture parts that perform reliably under tough conditions,” Garcia added.
