SLM Solutions and Honeywell jointly developing 3D printed aluminium alloy parameter sets for aerospace components

Germany-based metal additive manufacturing leader SLM Solutions, in collaboration with Honeywell, is developing 3D printed aluminium parts. Working with aluminium alloy F357, they are jointly producing parameter sets, which will deliver considerably improved material properties compared to parts manufactured through die-casting. The goal is to use these parameter sets to reduce manufacturing times and costs for the production of aerospace components with high layer thickness.

In 2019, Honeywell first started exploring AM aluminium parts and parameters using an increased layer thickness of 60 and 90 µm on a quad-laser SLM 500 Selective Laser Melting Machine. SLM Solutions was the supplier of generic aluminium parameter sets to Honeywell then to complete material qualification. However, now, the development of those parameter sets is said to have reached an "important milestone", citing material properties which exceed that of conventional die-cast parts and overall metallic properties for aerospace.

The material, a new beryllium version of Aluminium alloy A357, is highly sought in aerospace due to its lightweight properties, corrosion resistance, and desired mechanical properties such as high-strength across a wide temperature range compared to conventional aluminium alloys. The alloy also provides great weldability and can be readily post-processed via a number of techniques.

Dr. Sören Wiener, Senior Director Technology and Advanced Operations at Honeywell Aerospace, comments on his work with the SLM 500: “In particular, the open architecture system of the SLM machine provides huge advantages like high flexibility and parameter sets can be customised. With this open access strategy and the great support of SLM Solutions, we step forward to achieving our next goals."

Benjamin Haas, Product Manager for Materials & Parameters at SLM Solutions, explains: “It is a privilege to work together with one of the leading companies in the aerospace world. This way, we can learn a lot from each other leading to perfectly suited, industry proven solutions from which all of our customers can benefit.”