Renishaw, a company specializing in metal additive manufacturing systems, has entered into a strategic partnership with Metalpine, an Austrian producer of high-quality metal powders. The aim of this collaboration? To develop 3D printing solutions specifically adapted to the maritime sector. The companies are working together to design durable components that are capable of withstanding the extreme conditions of marine environments, where prolonged exposure to salt water accelerates corrosion and wear.
The project focuses on the use of copper-nickel alloys (CuNi) in powder form for 3D printing. These alloys are renowned for their anti-corrosion properties. Once treated by laser fusion, they form a protective layer that reinforces the resistance of parts in the aggressive marine environment. Two compositions were specifically studied: CuNi 10 (10% nickel, 90% copper) and CuNi 30 (30% nickel, 70% copper), each offering distinct characteristics in terms of laser behavior and mechanical performance.
Photo Credits: Renishaw/Metalpine
3D Printing for the Creation of More Durable End-Use Parts
The components were manufactured using Renishaw’s RenAM 500Q Flex, a state-of-the-art metal 3D printer designed for research and development. Its ability to change powder rapidly, combined with the Reduced Build Volume (RBV) accessory, enabled trials to be carried out with just 0.25 liters of powder, while simulating large-scale production conditions. This approach was decisive in optimizing printing parameters while minimizing material waste.
One of the main technical challenges of the project was the processing of copper in 3D printing. This metal reflects much of the laser energy, making it difficult to fuse. To overcome this obstacle, Renishaw’s team carefully adjusted key parameters such as laser power, scanning speed and trajectory spacing. These adjustments resulted in homogeneous powder fusion and the production of parts with excellent mechanical properties. In particular, it was observed that CuNi 30 alloy, due to its higher nickel content, offered better processability than CuNi 10.
Photo Credits: Metalpine
The collaboration between Renishaw and Metalpine highlights the potential of additive manufacturing to produce parts that are both robust and precise. It also represents a strategic solution for naval forces wishing to reduce their reliance on complex supply chains. By opting for in-house production of components via 3D printing, these organizations can limit operational interruptions, guarantee the availability of critical parts and enhance the sustainability of their operations at sea.
Alex Garcia, AM Design and Applications Engineer at Renishaw, concludes, “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 optimisation 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.” You can find out more about the collaboration HERE.
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*Cover Photo Credits: Renishaw