SAE Update - January 2022 - 26

TECH FOCUS:
MATERIALS
Additive manufacturing advancing
on multiple fronts, says expert
Different types of parts require different types of additive manufacturing processes.
high buy to fly ratios. Buy to fly is an
indsutry phrase used to describe a part that
requires a lot of raw material (buy) and
where that material is processed away as the
final part is made (fly). The industry average
is around 11:1, meaning that 11 kilograms of
titanium are bought to make 1 kilogram of
part. Beyond this paradigm, part unitization
can be accelerated with AM as complexity is
more affordably accomplished than in
legacy processes.
Within propulsion, parts that do not rotate
have the best opportunity. Engines tend to
have a higher quantity of more intricate or
complex parts, so the engine companies
have been quite active using AM to reduce
the overall part count and in some cases,
improve performance.
Space systems have a different business
case to use AM than all other industries.
Weight is a much higher premium to lift
payloads into space and couple this with very
few quantities compared to other industries.
In some applications, the longevity of the
26
January 2022
parts are quite limited as well, so the
requirements are different than a commercial
airplane than may need to last for 30 years.
Is there anything else you'd like to say?
Overall, I think the world of materials in for a
revolution. We are progressing out of an
stage where making a lot of very few things
was key. Now, we seem to be headed down
a path where a narrow range of
customization is possible and where weight
is becoming more of a premium. There is a
huge role for materials in this effort. To
achieve these benefits, the material
performance has to be reflected in the
design. AM is a team sport so while I think
the role of materials will increase relative to
the other disciplines in AM, it will tightly
coupled with the role of design and being
able to design for the various AM processes.
We are in a very early stage as an industry in
the awareness of AM and how to design for
AM. n
UPDATE
The Barnes Global Advisors

SAE Update - January 2022

Table of Contents for the Digital Edition of SAE Update - January 2022

SAE Update - January 2022 - Cov1
SAE Update - January 2022 - Cov2
SAE Update - January 2022 - 1
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