Renishaw and Metalpine Team Up to Produce AM Parts

Renishaw has collaborated with Metalpine, an Austrian producer of metal powders, to develop additive manufacturing (AM) solutions for marine applications. The partnership is focused on creating copper-nickel alloy (CuNi) powders for AM, to enable a major European naval force to manufacture replacement parts in-house using Renishaw's RenAM 500Q Flex system.

Operating in saltwater environments presents challenges for naval operations, with hydraulic components and other essential parts subject to accelerated wear and corrosion. The naval force in question chose to additively manufacture replacement parts in-house, opting for CuNi powder parts manufactured on a Renishaw RenAM 500Q Flex system.

Created with a blend of copper and nickel alloy, CuNi powders create a protective layer on the surface of components, preventing degradation, according to Renishaw. This makes them durable in marine conditions where parts are constantly exposed to moisture and sea elements. Engineers from Renishaw and Metalpine partnered to develop process parameters tailored to two specific copper-nickel alloys: CuNi 10, a combination of 10% nickel and 90% copper, and CuNi 30, using 30% nickel and 70% copper.

“Metalpine uses a stable and outstandingly efficient process to manufacture high-quality metal powders focused on particles with high sphericity and no pores. So, it is straightforward for us to develop and produce new powders,” explains Gerald Pöllmann, CEO of Metalpine. “Collaborating with the AM engineers at Renishaw was a great experience. The team quickly shared what they achieved with our powders during their qualification process, enabling us to create and deliver powders that fit the application perfectly.”

The powders were used in the RenAM 500Q Flex, an advanced metal AM system designed for R&D and pre-production applications. With an open-loop powder system, this machine allows for quick powder swapping, made for developing and optimizing material properties, part designs and process parameters, according to Renishaw. With the Reduced Build Volume (RBV) accessory fitted, material prove out can be performed with as little as 0.25 litres of powder, with the same processing environment and optics as the full-scale production system, Renishaw notes.

"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,” explains Alex Garcia, AM design and applications engineer at Renishaw. “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 optimization 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.”

For further information on Renishaw's RenAM 500 Flex AM system, visit the product page.

Sources: Press materials received from the company and additional information gleaned from the company’s website.