Alcoa, Pittsburgh, opened a state-of-the-art, 3D printing metal powder production facility at the Alcoa Technology Center. The facility will produce proprietary titanium, nickel, and aluminum powders optimized for 3D printed aerospace parts. Alcoa has also invested in a range of technologies to further develop additive processes, product design, and qualification.
Metal powders used for 3D printing durable, high-quality aerospace parts are available in limited quantities. Through this expansion Alcoa will develop materials with the specific properties needed to 3D print high-performance components. Alcoa has a long history of metal alloy development and has a 100-year history in aluminum metal powder production, primarily for rocket fuel, paint, and other products.
In addition to producing powders, the company is focused on advancing a range of additive techniques, including a new Ampliforge process—a hybrid technique that combines additive and traditional manufacturing. Using the process, nearly-complete-parts are designed and printed, then treated using a traditional manufacturing process, such as forging. The process enhances the properties of 3D printed parts, increasing toughness and strength versus parts made solely by additive manufacturing, and significantly reduces material input.
Alcoa has manufactured 3D printed products for the past 20 years and owns and operates one of the world’s largest hot isostatic pressing (HIP) complexes in aerospace. HIP technology strengthens metallic structures of traditional and additive manufactured parts made of titanium and nickel based super-alloys. Through the acquisition of RTI, Alcoa gained 3D printing capabilities in titanium and other specialty metals for the aerospace market and other growth industries.
Demonstrating its leadership in additive manufacturing, Airbus recently selected Alcoa to supply 3D printed titanium fuselage and engine pylon parts for commercial aircraft. Alcoa expects to deliver the first additive manufactured parts under the agreement later this year.
Image caption — Alcoa opened a state-of-the-art, 3D printing metal powder production facility located at the Alcoa Technology Center, the world’s largest light metals research center. Courtesy of Business Wire.
