Additive Manufacturing for product improvement at Red Bull Technology

Abstract

In Formula 1 racing, there is a strong motive for reducing component weight and thereby improving efficiency. This paper demonstrates the advantages Additive Manufacturing brings to the production of hydraulic components. The Direct Metal Laser Sintering (DMLS) production technique enables weight reductions to be attained by its geometric design freedom coupled with this material's attributes. The use of EOS Titanium Ti64 material for hydraulic components has been assessed by a hydraulic soak test at 25 MPa and no significant losses or failure occurred. The benefits to the efficiency of hydraulic flow have been measured using Particle Image Velocimetry (PIV) and the use of DMLS manufactured geometry has improved flow characteristics by 250% over that of the currently used techniques of manufacturing channels and bores.

An Overview of Densification, Microstructure and Mechanical Property of Additively Manufactured Ti-6Al-4V — Comparison among Selective Laser Melting, Electron Beam Melting, Laser Metal Deposition and Selective Laser Sintering, and with Conventional Powder

“…SLS is largely similar to the conventional PM and this explains that the microstructure of SLS Ti-6Al-4V is close to that of equilibrium state as with the PM or cast Ti-6Al-4V [79][80][81][82][83][84][85][86][87][88]. Figure 8 compares the microstructure of SLS Ti-6Al-4V with that of an HIP Ti-6Al-4V [81].…”

“…EOSINT M250X and EOISNT M270 are being used as the SLS machines for preparing AM Ti-6Al-4V [79][80][81][82][83][84][85][86][87][88]. The general working conditions and key machine/processing parameters are shown by Figure 5 and listed in Table 6.…”

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties

“…2), hence, validating powder recycling methodology for its use in SLS/SLM manufacturing. Other outstanding ecological performing indicators of SLS/SLM process include reduction in emissions because fewer raw materials need to be produced, design for light-weight structuring with a weight reduction and design for performance and indirect usage of toxic chemicals like lubricant or coolant in any measurable amount [24,25]. average porosity or impact energy obtained from these five values [22].…”

Structural performance of additive manufactured metallic material and cross-sections

“…Metal additive manufacturing is increasingly popular in the aerospace, automo-20 tive, defence and medical industries [14,15] due to its many advantages over traditional manufacturing techniques, such as casting, fabrication, machining, rolling and stamping. Conventionally manufactured objects often have simple geometries to aid manufacturing [4] whereas with new production techniques this need not be the case.…”