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Hybrid manufacturing of a hollow ship’s propeller : investigation from material characterization to implementation
Citation Link: https://doi.org/10.15480/882.9360
Publikationstyp
Conference Paper
Publikationsdatum
2024-04-04
Sprache
English
Author
Mecklenburger Metallguss GmbH, Waren, Germany
Mecklenburger Metallguss GmbH, Waren, Germany
Mecklenburger Metallguss GmbH, Waren, Germany
Mecklenburger Metallguss GmbH
Start Page
737
End Page
746
Citation
8th International Symposium on Marine Propulsors (smp 2024)
Contribution to Conference
Publisher
Norwegian University of Science and Technology, Department of Marine Technology
ISBN
978-82-691120-5-4
Peer Reviewed
true
The development of new manufacturing technologies is opening new prospects to produce components of maritime systems. Particularly in the production of ship propellers with small diameters (D < 5 m), the established sand-casting process can only be used competitively to some extent as a technology in today's market. Additive manufacturing technologies have not only developed rapidly due to their ability to produce near-net-shape components with complex geometry, but also offer various advantages over conventional processes in the area of individual component production. In addition to the geometry and design freedoms, production times, material consumption and, as a result, costs can be reduced enormously for small batch sizes.
Ship propellers in the superyacht sector combine the restrictions of the conventional sand-casting process and the potentials of additive manufacturing. A propeller with four blades and a hollow blade structure is being developed as part of a research project. Together with Fraunhofer IGP and the University of Rostock, investigations were carried out into the WAAM process using copper-based alloys. In addition to the conventional pulsed arc process, the Cold Metal Transfer (CMT) process was used to investigate the three welding filler materials CuAl8Ni2Fe2Mn2, CuAl9Ni5Fe3Mn2 and CuMn13Al8Fe3Ni2. Results for a material and process characterization are shown based on buildup welds in the form of wall-shaped structures. Sensitive component areas were then selected to determine process variables for additive and subtractive manufacturing as part of the process development. Testing of different buildup strategies as well as different milling tools is also part of the investigations. To ensure a reduced core drop load on the hollow structure, there is a continuous alternation between buildup welding and milling, both on the external and internal surfaces. A techno-economic comparison between the manufacture of the demonstrator propeller using the WAAM process and sand casting is presented in conclusion.
Ship propellers in the superyacht sector combine the restrictions of the conventional sand-casting process and the potentials of additive manufacturing. A propeller with four blades and a hollow blade structure is being developed as part of a research project. Together with Fraunhofer IGP and the University of Rostock, investigations were carried out into the WAAM process using copper-based alloys. In addition to the conventional pulsed arc process, the Cold Metal Transfer (CMT) process was used to investigate the three welding filler materials CuAl8Ni2Fe2Mn2, CuAl9Ni5Fe3Mn2 and CuMn13Al8Fe3Ni2. Results for a material and process characterization are shown based on buildup welds in the form of wall-shaped structures. Sensitive component areas were then selected to determine process variables for additive and subtractive manufacturing as part of the process development. Testing of different buildup strategies as well as different milling tools is also part of the investigations. To ensure a reduced core drop load on the hollow structure, there is a continuous alternation between buildup welding and milling, both on the external and internal surfaces. A techno-economic comparison between the manufacture of the demonstrator propeller using the WAAM process and sand casting is presented in conclusion.
Schlagworte
Additive manufacturing
wire arc additive manufacturing WAAM
mechanical testing
path planning
DDC Class
620: Engineering
Publication version
publishedVersion
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Name
Klotzerfreese-HybridManufacturingOfAHollowShipsPropellerInvestigationsFromMate-1186-1-final.pdf
Size
1.71 MB
Format
Adobe PDF