CuNi powder formulations for metal additive manufacturing target marine applications.
The maritime sector is a growing market segment for metal additive manufacturing (AM), particularly in maintenance and repair applications. The latest example of this trend is a collaboration between metal AM machine manufacturer Renishaw and Austrian metal powder provider Metalpine.
The two companies have come together to develop copper-nickel alloy (CuNi) powders with an eye toward enabling European naval forces to produce their own replacement parts in house. One of the biggest challenges for metal AM parts in marine applications is the corrosive effect of salt water, particularly for hydraulics. That’s why the Renishaw and Metalpine are focusing on CuNi powders, which can be used to create a protective layer on component surfaces to make them more durable.
More specifically, engineers from the two companies have been working on optimizing the process parameters for two particular powders: CuNi 10 (90% copper, 10% nickel) and CuNi 30 (70% copper, 30% nickel).
The powders were used in the RenAM 500Q Flex, which is designed for R&D and pre-production applications. With an open-loop powder system, the machine allows researchers to swap in different powders, making it suitable for developing and optimising material properties, part designs and process parameters. According to Renishaw, the Reduced Build Volume (RBV) accessory enables material prove out to be performed with as little as 0.25 litres of powder while maintaining 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, a Renishaw AM design and applications engineer, in a press release. “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.”
