Our client required a robust injector that would push the limits of design and functionality. We have made a lighter, more efficient, AM-built application that opens up new opportunities to leverage existing expertise.
The Challenge
Injectors are widely used in the Aerospace industry for fluid transportation. The varying use cases — depending on their needs — require a significant level of customization. Because of this, they are produced in large numbers and kept in storage as backups. This avoids long lead times of up to 20 weeks in case of failure and guarantees uptime for a part crucial to the company’s capital.
Solution
With additive manufacturing, applications can be printed on demand, reducing waste from having to overproduce to make things financially viable. This also reduces lead times, and the need for storage can be minimized through digital inventories, on-premises manufacturing, and higher part-performing parts. In addition, additive manufacturing can disclose new business models and solutions in the spare parts business, such as cutting out prototyping by casting
Technological Aspects: Benefits of DMLS in Injector Manufacturing
The Injector built up by means of traditional technology was typically characterized by a large number of parts, joined together through the welding or brazing process.
A typical product was so composed:
80 about single elements
Brazing joint in the critical joint (fuel/oxidizer interface);
Welding joints for the internal parts to be joined.
The innovative 3D Printed Injector are instead composed of:
1 single elements
No brazing joints in the critical joint. So no leak of any propellants
No welding joints, that can represent a weak point of the structure;
The main reasons for applying Additive Manufacturing in the Aerospace components manufacturing, instead of traditional technology, are further explained:
Increase Performance
Reduce mass (lightweight construction, resource efficiency);
Increase efficiency (combustion processes, free formed surfaces/channels);
Integrate closed, complex internal channels (e.g. injectors geometry);
Simplify Production and Increase Production Safety
Integration of numerous functions in one single component without assembly efforts;
Even complex objects will be manufactured in one process step;
Rapid Manufacturing
No need for special tools: direct production possible without costly and time-consuming tooling;
No need for long-lead procurement of billet material;
Complex Shaped Parts
Allow the alternative design / manufacture of parts requiring machining of more than 80 % of the initial material;
Increasing object complexity will increase production costs only marginally.
Materials for AM built injector – Ti6Al4V Eli
The choice of material, Ti6Al4V Eli (Titanium alloy), is a suitable selection due to its lightweight strength, and excellent resistance to corrosion and temperature. It is commonly used in aerospace applications like aircraft jet engines and spacecraft due to its ability to reduce fuel costs
Inspections, Quality Control, and Certifications
Objectify Technologies demonstrates a commitment to quality and compliance by obtaining relevant certifications and labels. Specifically, the AS9100D certification is crucial for aerospace and defense companies, as it ensures adherence to stringent quality standards, crucial in industries where equipment failure can have severe consequences.
The Facts
Using Direct Metal Laser Sintering (DMLS) technology, Objectify Technologies produce a single-piece injector without brazing or welding joints, making it more robust and eliminating potential weak points. Objectify Technologies successfully built the injector on the EOS M400-4 in its application center in India.