3d metal printing solutions · engineering industry maintenance reproduction optimisations •...

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3D Metal Printing Solutions

2/25/2019 2

POWDER LAB

ACADEMIC CELL

INDUSTRIAL SITE

ENGIE 3D Metal Printing Capabilities: From Powder to Part Production

SLM 280

280 x 280 x320 mm³

New material development: Ni-alloys and Al-alloys

• SLM 500

• 500 x 280 x 365 mm³

• RVS 316L

Powder Qualification & New

Material Assessment

(SLM125 + Powder Lab)

• POWDER CHARACTERIZATION

• 3D SCANNING &

REVERSE ENGINEERING

• APPLICATIONS

• (RE)DESIGN

• CERTIFICATION

• RESEARCH AND DEVELOPMENT

• COMPETENCE CENTER

• EXTENSIVE TESTING

• MECHANICAL WORKSHOP

(POST PROCESSING)

2/25/2019 3

Layer thickness of 50 µm

What is 3D printing? AM? The selective laser melting technique..

1

2

3

4

5 Removal support

and postprocessing

ENGIE AM integrated factory – a total solution provider

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(Re-)Design Part Production

Monitoring

Post-

Processing

Material

Feedstock

Process

ValidationPart

Geometry

3D Metal

printing

Milling

Turning

Welding

(Casting)

…

• Drawing

• 3D scan

&

Reverse

engineering

25/02/2019 Cost cutting in spare part management. Ever thought of Additive Manufacturing? webinar 5

Benefits for Complex parts manufacturing

Freedom of

DesignOptimisations

Total cost

reduction

Lead time

decrease

• Obsolete part manufacturing

• Spare part management

• Fast reiteration, shorter development cycle

• Flow optimisation

• Heat transfer optimisation

• Weight reduction

• Designs not possible via conventional

machining

• Part customization

• Integrated functionality

• New possibilites

“Internal structures solution”

• Multiple part assembly to single part

• Replacement of casting (small series)

“All-in-once build up”



Freedom of

DesignOptimisations

Total cost

reduction

Lead time

decrease








machining








Heat transfer optimisation: Fuel injection nozzle for a heavy fuel boiler application modified to fire BPA

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✓ Application: Fuel injection nozzle for BPA

✓ Customer: BU Generation Cluster Gas

Benelux

✓ Material: Stainless steel 316L

✓ Dimensions: 80 x 160 x 420 mm

✓ Problem: BPA needs to be warm

enough to be a fluid. This is

done by steam tracing. On certain

locations BPA solidifies. This

creates poor operation and turns

into high maintenance costs.

Original design

2/25/2019 ENGIE Thematic Lab 3D Printing

Design optimization and printing of an injection

nozzle optimized for firing new fuel type

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Original Design

Design Validation by CFD:

flow distribution and mass flow

Production & Post-Processing

Quality assessment

AM Design

4

Field Testing 71

New “conventional” Design

3 5✓

✓ ✓2 6

9

Conformal stream tracing (in

blue) surrounding fluent fuel

path (in orange)

3D Print


Heat transfer optimisation: Fuel injection nozzle for a heavy fuel boiler application modified to fire BPA

✓ Application: Fuel injection nozzle for BPA

✓ Customer: BU Generation Cluster Gas

Benelux


✓ Dimensions: 80 x 160 x 420 mm

✓ Project scope:

- Re-design and 3D printing activities to:- Optimize fuel preheating

- Reduce maintenance cost and risks

- Reduce assembly (1 piece instead of 6)

- Facilitate internal fuel channel cleaning

- Improve jetting for better atomization



Freedom of

DesignOptimisations

Total cost

reduction

Lead time

decrease








machining

• Freedom of design








Part for venture system in Chalk atomizer for ENGIE Fabricom

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✓ Application: Chalk atomizer

✓ Customer: ENGIE Fabricom


✓ Dimensions: 180 x Ø115 mm

✓ Function:

• Prevention of full suction of powder

• Lateral gauze

• Engineering of dosing of powder


Part for venture system in Chalk atomizer for ENGIE Fabricom

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✓ Application: Chalk atomizer

✓ Customer: ENGIE Fabricom



✓ Project scope:

- Complex part design and production

driven by AM capabilities

- Printed in 2 days!

- New product development

- Evaluation of design capabilities for

increased efficiencyChalk atomizer conceptually designed and

produced based on AM capabilities


DIFFICULT VIA

CONVENTIONAL MACHINING



Freedom of

designOptimisations

Total cost

reduction

Lead time

decrease








machining

• Freedom of design









1High cost per

part for small

series

2

Warehouse costs for

slow moving parts

3Plant down-time due

to delivery of critical

spare parts

4

Parts

obsolescence

Maintenance / Spare part management

New Solutions possible with

Additive Manufacturing

Impeller for

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✓ Application: Impeller for oil & gas

✓ Customer: Total



✓ Project scope:

- Reverse engineering of ex-service component

- Design optimization to facilitate AM production

- Full post-processing programme (heat treatment,

machining, balancing) in our integrated factory.

- Internal qualification process (tensile testing,

hardness, metallurgical assessment…)

- Lead time: 2 weeks!

2/25/2019

Impeller for oil & gas applications:

from 3D scanning to post-processing

Maintenance & Spare Part ManagementImpeller for oil & gas

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Reverse Engineering

Ex-service component

Production2

Post-processing:

HT, machining, balancing5

Quality assessment & mechanical testing

1Build strategy &

design optimization3

4 6

Field Testing &

Implementation7✓

✓

✓ ✓ ✓

✓ ✓


3D Metal Printing Solutions for Complex parts

Freedom of

DesignOptimisations

Reduced total

cost

Lead time

decrease



Engineering

Industry

Maintenance

Reproduction

Optimisations

• Design for new product development

• New possibilities

• Integrated Optimised functionality

• Fast lead time manufacturing / Obsolete part manufacturing

Of Complex components and Casted parts

• Small series production

• Optimisations on conventional components for

Better part performance

ENGIE Fabricom 3D Metal Printing Services

Full Training

course

Scan for high potential applications for AM manufacturing

(Re)-Design

Training

Low cost production for small series

Extensive

TestingExtensive testing program (for printed parts)

Production

Market situation, metal powder characterization, software

tools, process parameters and best practices, hands-on

session to produce functional products18

AM scan

Redesign course for funtional optimisation and printability

3D Application Development engineer

[email protected]

+32473192872

Vitshoekstaat 5, Zwijndrecht 2070

Engie Fabricom 3D Metal Printing Services

00/00/2015 19TITRE DE LA PRESENTATION ( MENU "INSERTION / EN-TETE ET PIED DE PAGE")

mailto:[email protected]

3d metal printing solutions · engineering industry maintenance reproduction optimisations •...

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