36 Additive Manufacturing for Circular Manufacturing: Trends …
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added the material (Stellite) directly on the worn surface, consequently prolonging
the expected lifetime of the turbine (Matsumoto et al. 2016).
Remanufacturing of dies and molds is another example of DED applications.
Figure 36.9 illustrates a process of remanufacturing worn-out dies. The region
containing cracks was processed by pocket machining, and was restored by laser
metal deposition (a DED type), and was finished by post machining (Fig. 36.9). In
a case where a company applied DED to the repair of a die, the service life of the
repaired die was extended by 250% (Ahn 2016). Moreover, DED-based remanufacturing can lead to extended product lifetime, shorter lead time, cost and energy
savings (Ahn 2016). AM process has been applied not only to the repair of worn-out
dies, but also to the remanufacture of dies for new products and processes (Matsumoto
et al. 2016). There is also a study on remanufacturing dies with the hard-faced layer
consisting of a wear-resistant material (Ahn 2016).
There were also application cases of other metal 3D printing techniques besides
DED. Siemens Power Service, for instance, applied the powder bed fusion process
for the repair of damaged gas turbine burner tips wherein the tips were machined
before they were placed into the powder bed of a selective laser melting machine,
and before new tips were built onto the machined surface (Fig. 36.10) (Matsumoto
et al. 2016).
There are explanatory studies on assessment of energy use and environmental
impacts of AM processes (Kellens et al. 2017). The merits of AM techniques, ultimately, should be judged based on not only their technical and economic advantages,
but also their environmental effects.
In India, metal 3D printing is mostly looked at in the context of repairing,
refurbishing, and remanufacturing old components. Examples of the regional R&D
include refurbishment of railway components with laser-based DED; and repair of
forging dies with the use of wire-arc AM.
Fig. 36.9 Illustration of die
remanufacturing by DED
. (Source Okuma
corporation)
527
added the material (Stellite) directly on the worn surface, consequently prolonging
the expected lifetime of the turbine (Matsumoto et al. 2016).
Remanufacturing of dies and molds is another example of DED applications.
Figure 36.9 illustrates a process of remanufacturing worn-out dies. The region
containing cracks was processed by pocket machining, and was restored by laser
metal deposition (a DED type), and was finished by post machining (Fig. 36.9). In
a case where a company applied DED to the repair of a die, the service life of the
repaired die was extended by 250% (Ahn 2016). Moreover, DED-based remanufacturing can lead to extended product lifetime, shorter lead time, cost and energy
savings (Ahn 2016). AM process has been applied not only to the repair of worn-out
dies, but also to the remanufacture of dies for new products and processes (Matsumoto
et al. 2016). There is also a study on remanufacturing dies with the hard-faced layer
consisting of a wear-resistant material (Ahn 2016).
There were also application cases of other metal 3D printing techniques besides
DED. Siemens Power Service, for instance, applied the powder bed fusion process
for the repair of damaged gas turbine burner tips wherein the tips were machined
before they were placed into the powder bed of a selective laser melting machine,
and before new tips were built onto the machined surface (Fig. 36.10) (Matsumoto
et al. 2016).
There are explanatory studies on assessment of energy use and environmental
impacts of AM processes (Kellens et al. 2017). The merits of AM techniques, ultimately, should be judged based on not only their technical and economic advantages,
but also their environmental effects.
In India, metal 3D printing is mostly looked at in the context of repairing,
refurbishing, and remanufacturing old components. Examples of the regional R&D
include refurbishment of railway components with laser-based DED; and repair of
forging dies with the use of wire-arc AM.
Fig. 36.9 Illustration of die
remanufacturing by DED
. (Source Okuma
corporation)