● 3D Systems and HII have jointly developed CuNi30 to be able to produce traditional castings, with a production time reduced by 75 %
● Direct copper-nickel (CuNi30) printing achieves an average relative density of 99.88 %, a significant improvement over casting
● The material will be commercialized to meet the current need for alternatives to CuNi casting in the naval, offshore oil and gas, chemical and nuclear sectors.
3D Systems has announced the availability of CuNi30, a corrosion-resistant copper-nickel alloy, for use with its DMP Flex 350 metal 3D printer. The material is the result of its collaboration with HII's Newport News Shipbuilding division to develop materials and parameters suitable for powder laser melting additive manufacturing technology. The expertise of the two companies has made the development of CuNi30 possible, enabling Newport News Shipbuilding to use additive manufacturing in place of its traditional molding technologies. Direct printing of CuNi30 parts meets Newport News Shipbuilding's demand for a space-saving material that is easy to combine. It improves supply chain efficiency, reducing delivery times by 75 % and cutting inventory costs.
Copper-nickel alloys are commonly used in salt water, oil and acidic environments due to their excellent corrosion resistance and antimicrobial and anti-algae properties, which enable them to resist algae growth even in the event of prolonged exposure to water. CuNi30 is often used to manufacture pipe fittings and valves in the naval sector (particularly in shipbuilding and repair), the offshore oil and gas industry, the chemical industry and the nuclear sector. These alloys also boast stable mechanical, physical and thermal properties (from 400°C to -270°C), making them suitable for cryogenic applications. Difficult to cast, CuNi alloys often require costly rework and reinspection cycles to meet quality standards. Production lead times are therefore very long, and few suppliers have the capacity and willingness to produce quality material. HII has identified the great potential offered by additive manufacturing, provided it can qualify the material, the material and the DMP process for its production components. With this in mind, the company teamed up with 3D Systems.
" 3D Systems has earned a reputation as a trusted partner in advanced R&D and the commercialization of new additive manufacturing materials and applications. ", said Dr. Michael Shepard, Vice President, Aerospace and Defense Segment, 3D Systems. " We've been working with the U.S. Navy for decades, innovating in fields as diverse as aircraft parts and submersible components. Our latest project with Newport News Shipbuilding has led to the development of a copper-nickel alloy specifically designed for additive manufacturing, which delivers higher part density and better mechanical properties than traditional casting. We look forward to seeing how direct metal printing and CuNi30 can accelerate Newport News Shipbuilding's production workflow and innovation efforts. "
" We have reached an important milestone in the development of a CuNi alloy in collaboration with 3D Systems. " said Dave Bolcar, vice president of engineering and design for Newport News Shipbuilding, a division of HII. " Several years of research and development, in partnership with 3D Systems, culminated earlier this year in the production of a Corrosion Performance Design Guide for direct printing in a nickel-based alloy. We look forward to extending our parameter development efforts with 3D Systems to other alloys of particular interest to our industry. These developments enable us to go even further in using additive manufacturing in our platforms to bring additional benefits to our customers in terms of quality, timing and performance. "
3D Systems intends to add CuNi30 to its portfolio of innovative materials to enable other sectors to produce corrosion-resistant parts using direct metal printing. The material is scheduled for commercial release in the fourth quarter of 2022.