The amazing materials that are produced through additive manufacturing (AM) and 3D machining often require post-processing heat treatments before these become final components that launch into space. What are the trends of AM/3D outside our planet, and what technical resources are available to you as you make one step into this field? This original content piece from the Heat Treat Today editors will help you understand where technology stands in 2024.
Why Does AM/3D Go to Space?
A broad spectrum of industries have found the appeal of additively manufactured parts, industries ranging from mining to medical and automotive to space. Much of this has to do with complexity of components that new engineering techniques require, the desire to save on material costs, and the ability to condense lead time. For some, additive manufacturing is becoming essential to the space industry; as Tobias Brune, head of the Business Unit Additive Manufacturing at TRUMPF, has commented, “With our 3D printing technology, we are driving the commercialization of the space-travel industry. If you want to be successful in the space-travel industry today, you have to use additive manufacturing.”
When should you expect this transition? Now.
In January of this year (2024), the first metal 3D printer for space was launched to the Columbus module of the International Space Station (ISS). This is a very active, integrated sense of seeing AM in the aerospace industry, and test runs with this equipment will ensue.
Source: ESA
The Exploration Company in Europe plans to use 3D printers from TRUMPF (laser specialist) to print core components in engines for spacecrafts. The intent: missions in Earth’s orbit and to the moon.
Heat Treat & thermal Processing Requirements of Post-Processing AM
If you are going to get involved in AM, it is essential to have the right equipment. One of the most talked about equipment is hot isostatic pressing (HIP) technology. Often, heat treat operations use HIP equipment for post-process heat treating in order to get the solid part they desire. For the most part, commercial heat treaters have positioned themselves to handle the R&D required to navigate the terrain of overcoming processing challenges of new/complex parts and creating standardizations. However, private R&D facilities and departments are also building out their capabilities to handle AM in HIP.
However, so also have vacuum furnaces been a key leader in heat treating AM components. Here, commercial heat treaters have also made moves to expand their equipment/process offerings to accommodate AM parts.
So also do atmosphere considerations need to be considered, with gasses like H2 competing trying to capture the limelight.
Continue the Exploration: AM/3D Articles for Space
Looking for an introduction to the AM/3D topic for heat treaters? Begin with this article by Animesh Bose, an engineering pioneer: “The Role Of Heat Treat in Binder Jetting AM for Metals.” The article uncovers the history of one of the most important types of AM/3D manufacturing — binder jetting AM.
Then, take a step over for an industry focus on what “heat treatments for space” look like. Mike Grande eloquently summarized the current processes needed in space in this editorial from the March 2024 Aerospace print edition. Read “The Role of Heat Treatment in Space Exploration” in the digital edition of the magazine.
In-house or commercial? This article presents critical considerations of space components — with a particular emphasis on the importance of AM/3D — when considering how to grow your processing expertise and capabilities. Several examples from the frontlines of R&D are presented by Noel Brady in his article. Read the editorial, “Thermal Processing for Space and Additive Manufacturing,” for excellent illustrations.
Finally, hone in on the topic with a case study about developments in HIP technology for space component post-processing. This article begins with context confronting issues of structural integrity, especially of complex space components, with HIP. Andrew Cassese gets to the case study towards the end of his article, “High Pressure Prepares Parts for Space.”
