MRO service providerLufthansa TechnikandPremium AEROTEC, an空中客车subsidiary, have broken new ground by developing the world’s first 3D printed load-bearing metal part approved for use on an aircraft.
Created at Lufthansa Technik’s Additive Manufacturing Center, the landmark spare part is an ‘A-Link’ for use in the IAE-V2500 engine’s anti-icing system. The two-shaft turbofan engine powers Airbus’ A320 family of aircraft.
承载组件是同类产品中的第一个由航空认证EU Aviation Safety Agency(EASA) and will be series 3D printed by Premium AEROTEC at its production site in Varel, Germany.
汉萨技术技术的首席运营官Soeren Stark说：“我们一直在为飞机舱生产组件，这是多年使用3D打印多年的绝大多数由塑料制成的。现在，我们能够证明，在机舱外使用结构相关的金属零件也可以加性地制造并批准用于飞行操作。”
A new age for the A-Link
Inside the IAE-V2500’s inlet cowl, a set of nine A-Links is used to secure a ring-shaped hot air duct in place, which helps prevent ice buildup during flight. They’re made of titanium and often see temperatures of up to 300°C. Due to the vibrations experienced in the air, these A-Links commonly wear at their mounting holes so they need to be replaced by spare parts every few years.
Traditionally, the part is manufactured via a metal forging process to ensure the mechanical performance necessary for end-use. By leveraging laser powder bed fusion (LPBF) instead, Premium AEROTEC and Lufthansa Technik have eliminated the need for any tooling whatsoever, yielded greater material savings, and even lowered overall manufacturing costs.
Surpassing conventional manufacturing
当涉及金属添加剂制造时，零件的机械性能受到打印雷电竞充值参数的严重影响，因此过程资格是一个复杂但至关重要的冒险。为了鉴定A-Link过程，Premium Aerotec使用原型样品进行了“大量”打印测试，以微调构建的可靠性和可重复性。在添加剂制造中，相同零件之间的尺寸可变性总是值得关注的，但是EASA认为A-Links在这方面的安全。雷电竞充值
One of the aims of the testing was to match the performance of the forging process but the firm managed to 3D print the A-Links with superior tensile strength to their conventionally manufactured counterparts. Impressive.
As part of the certification process, Lufthansa Technik expanded the capabilities of its EASA Part 21/J development facility to also include 3D printed metal parts. On the other hand, the project also marks the first time Premium AEROTEC has supplied printed series components to a customer outside the Airbus Group. The first of the 3D printed A-Links will be integrated into the Lufthansa fleet in due course.
“Premium AEROTEC is an international pioneer and technology leader in the additive manufacturing of aerospace components. Our company has already been applying this technology in the series production of complex structural components since 2016,” said Dr. Ulrich Weber, COO at Premium AEROTEC. “I am very pleased that in cooperation with Lufthansa Technik we can now once again demonstrate our comprehensive expertise in 3D printing.”
Looking ahead, the partners intend to one day take the A-Link a step further and redesign the part’s geometry for additive manufacturing, further increasing material efficiency while preserving strength and function.
尽管到目前为止，承载零件一直是一个梦想，但在航空和航空航天中的3D打印零件并不是新的壮举。就在这个月，意大利国防承包商LeonardoqualifiedDesktop MetalsubsidiaryAidroas a supplier of3D printed parts for its helicopters. Since gaining accreditation, the firm has begun working with Leonardo to create flight-ready parts for its rotorcraft, a lineup that includes civil and military helicopters.
Elsewhere,GE Aviationrecently became the first company to offermetal additive manufacturing for commercial jet engine component repairs. Specifically, the firm’s Loyang facility in Singapore has become the first MRO facility worldwide with approval to apply 3D printing in this manner.
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Featured image shows the 3D printed A-Link. Photo via Premium AEROTEC.
