Case 3d metal printing (DMLS): microreactor for oil refining
"The military come, ask to print some kind of thing the size of a matchbox, immediately buy a printer and disappear" from a conversation with suppliers of 3d-printers
In the photo on the right, Elon Musk’s tweet that they printed a detail of a rocket engine made from a heat-resistant nickel-chrome alloy (Inconel) on an EOS 3d printer.
Later, at the presentation there was information that SuperDraco had boarding engines fully printed on a 3D printer, each of which has a thrust of about eight tons.
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I already wrote about how things are going on in the world with 3d printing services on Habré , since then I became interested in what 3d-printers on metal are capable of. For a start, I tried to find a place in Moscow where you can touch / pofot this device, but faced difficulties, they say € 200,000, and you are with dirty hands, or these printers are located on the territory of military / space objects, which cannot be allowed there.
But there were St. Petersburg colleagues who shared information about how they created the microreactor on a 3d printer (from the same company as Elon Mask).
Case from St. Petersburg service for 3d printing:
Customer : Russian oil refining company
Order : microreactor for oil refining
Requirements : temperature up to 600 ° C, pressure up to 100 atmospheres, work in the environment of hydrogen and hydrocarbons, service life - 12 years.
UPD (06/06/2014): Post on Habré (October 5, 2012)
The rocket engine printed on a 3D-printer
(A friend with the nickname RocketMoonller demonstrated a liquid rocket engine (LRE) printed on a 3D printer. )
Learn more about DMLS technology
about printer EOS M290
and about microreactor
About technology
Expand
Wikipedia article on Direct metal laser sintering
Selective laser melting (SLM) is an additive manufacturing process that uses CAD file data as a digital source of information and energy in the form of a high-power laser beam (usually a ytterbium fiber laser) to create three-dimensional metal parts by fusing fine metal powder particles together.
Printing using DMLS technology is carried out as follows: the smallest metal powder is distributed in a thin layer using a covering mechanism or roller on the platform, which descends vertically.
The simulation process is performed by a laser melting the powder layer by layer, thus forming the finished object. The procedure takes place in a closed chamber; after printing, the model cools down and is cleared of powder residues.
microchips
Selective laser melting (SLM) is an additive manufacturing process that uses CAD file data as a digital source of information and energy in the form of a high-power laser beam (usually a ytterbium fiber laser) to create three-dimensional metal parts by fusing fine metal powder particles together.
Printing using DMLS technology is carried out as follows: the smallest metal powder is distributed in a thin layer using a covering mechanism or roller on the platform, which descends vertically.
The simulation process is performed by a laser melting the powder layer by layer, thus forming the finished object. The procedure takes place in a closed chamber; after printing, the model cools down and is cleared of powder residues.
microchips
About printer
Expand
EOS (Electro Optical Systems, Germany)
EOS M290
Machines of the “M” series are used for the manufacture of multi-purpose molds, special tools, parts from special alloys for the aviation and aerospace industries.
Dimensions of the construction area 250x250x215 mm.
Depending on the material used, the construction speed of the part is 7.2-72.0 cm3 / h, the thickness of the construction layer is 20-100 microns, the laser power is 400 W,
laser spot diameter of 100-500 microns.
New metal-powder compositions are proposed to consumers:
- Cobalt-chrome alloy (CoCr);
- alloys of titanium;
- stainless steel;
- Inconel alloy (high-temperature nickel-based alloy),
- tool steel.
Data preparation
PC with Windows system
Software: EOS RP Tools; EOSTATE; Magics RP (Materialize)
Format: STL (option - converter from all standard formats)
Network: Ethernet
Certification: CE, NFPA
maintenance videos
EOS M290
Machines of the “M” series are used for the manufacture of multi-purpose molds, special tools, parts from special alloys for the aviation and aerospace industries.
Dimensions of the construction area 250x250x215 mm.
Depending on the material used, the construction speed of the part is 7.2-72.0 cm3 / h, the thickness of the construction layer is 20-100 microns, the laser power is 400 W,
laser spot diameter of 100-500 microns.
New metal-powder compositions are proposed to consumers:
- Cobalt-chrome alloy (CoCr);
- alloys of titanium;
- stainless steel;
- Inconel alloy (high-temperature nickel-based alloy),
- tool steel.
Data preparation
PC with Windows system
Software: EOS RP Tools; EOSTATE; Magics RP (Materialize)
Format: STL (option - converter from all standard formats)
Network: Ethernet
Certification: CE, NFPA
maintenance videos
About 3d printing service
What it looks like in theory
As it was in reality
Experts on the basis of the drawings developed a 3D model of the microreactor.
After which the model was printed in stainless steel.
After printing, the reactor outside was finally treated (polished), threaded, and the hydrogen supply fitting was screwed into the side.
For example (at the request of the customer) printed product in the "cut", so that the customer can assess the print quality.
Microreactor size: height about 150 mm, external diameter about 50 mm.
The part was printed at about 16 hours (if 10 parts were printed at once simultaneously - this also took 16 hours)
Representatives of the 3d printing service were invited to participate in the testing of a microreactor at a standard reactor facility (the orange frame indicates the location of the microreactor - it is under thermal insulation).
A series of tests was carried out for several months. The operation mode of the installations is continuous (24 hours a day). The pressure in the reactor was from 30 to 50 atmospheres (depending on the design of the experiments) temperature from 150 to 500 degrees Celsius.
test process
The reactor received high-octane gasoline components (required for the production of Euro-5 gasoline)
hydrogen distribution in the reactor chamber. The color gradation shows the rate of hydrogen.
After successful tests, the customer decided to order a batch of microreactors printed on a 3D printer.
The cost of a microreactor was about $ 500, which is about 10-15 times cheaper for similar microreactors (manufactured by traditional methods).
The process of traditional manufacturing is welding, tokarka, prefabricated construction. (Cost $ 5000-7500 apiece)
Finally, a few more products printed in St. Petersburg 3d-service:
oil refining manifold
product with internal cooling system (built-in heat exchanger)
"Pipe bundle" - part of the flow distribution system (liquid and gas)
Source: https://habr.com/ru/post/227961/
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