MSU Technologies

High Speed Additive Metal Manufacturing Process

FABRICATED GREEN HEAT EXCHANGER PLATES BY SEAM PROCESS SINTERED STACKED HEAT EXCHANGER ASSEMBLY

Executive Summary

Metal additive manufacturing is an attractive process for producing highly complex and tailored components from superalloys for high temperature applications. However, the processes can be slow and are not scaleable for large volume production. Researchers at Michigan State University have recently developed an efficient additive manufacturing process for metal parts that is scalable, low cost and creates parts with very high relative densities with no geometrical distortion. The process can be also used to make complex structures with enclosed channels.

Description of the Technology

The technology is based on an additive manufacturing process using UV light curing of mixture composed of a photopolymer and metal powders termed SEAM (scalable and expeditious additive manufacturing). Layers of powder suspension are cured with digital UV light projection over in a layer by layer process followed by debinding and sintering to create a dense part. The process also includes a two step partial curing process and may include co-debinding and co-sintering of multiple parts. Experiments have been conducted using stainless steel, copper and aluminum. The technology has also been demonstrated with a Haynes 214, Nickel based superalloy to manufacture parts for a high temperature super critical CO₂ heat exchanger (photo above).

Benefits

Allows large building platform
High speed of manufacturing, lowers costs
High part density achieved up to 99.5% relative density with no geometrical distortion
Superior surface roughness compared to laser sintered process
Micron level accuracy
Scalable manufacturing process allows multiple parts to be formed at the same time
Allows production of parts with enclosed channels and complex internal structure

Applications

Parts for high temperature applications including engine turbine blades, nuclear reactors, turbochargers, heat exchangers
Automotive parts
Aerospace parts
Medical / Dental parts and devices
End of arm tooling
Jewelry