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Sunday, April 10, 2016 10:36:38 PM
RE:Hmmm....Alcoa process...Ampliforge
This looks like the patent: Methods for producing forged products and other worked products. It may not be the correct or only patent involved. There are five other patents referenced and included. "Each of these applications is incorporated by reference in their entirety herein."
After a VERY brief examination, I don't believe that the AM method is specifically identified. It looks like it's a method to combine AM items with other components. It doesn't look like Alcoa is identifying a new AM method of their own but is describing a process to incorporate AM components with other components to make a larger item. This looks like additive manufacturing where it's needed/desired and conventional manufacturing where it's not to produce a single part made up of two or more components.
Alcoa Expands R&D Center to Deepen Additive Manufacturing Capabilities - September 3, 2015.
Selected portions of the press release:
Demonstrating this integrated strategy, the Company today unveiled its Ampliforge™ process, a technique combining advanced materials, designs and additive and traditional manufacturing processes. Using the Ampliforge™ process, Alcoa designs and 3D-prints a near complete part, then treats it using a traditional manufacturing process, such as forging. The Company has shown that the process can enhance the properties of 3D-printed parts, such as increasing toughness and strength, versus parts made solely by additive manufacturing. Further, the Ampliforge™ process significantly reduces material input and simplifies production relative to traditional forging processes. Alcoa is piloting the technique in Pittsburgh and Cleveland.
Combination of Process and Design: Alcoa will further its development of advanced 3D-printing design and manufacturing techniques—such as Alcoa’s Ampliforge™ process—to improve production speeds, reduce costs, and achieve geometries not possible through traditional methods. Direct production of 3D-printed metal parts represents a new way to manufacture aerospace components and requires a new suite of innovative design tools to realize its full potential. By connecting our materials scientists with our manufacturing experts, we enable a rapid development feedback loop to inform new software tools and processes that take full advantage of additive capabilities.
This expansion of the Alcoa Technical Center builds on Alcoa’s additive manufacturing capabilities in California, Georgia, Michigan, Pennsylvania and Texas. The Company has been creating 3D-printed tools, molds and prototypes for the past 20 years and owns and operates one of the world’s largest HIP (Hot Isostatic Pressing) complexes in aerospace, a technology that strengthens the metallic structures of traditional and additive manufactured parts made of titanium and nickel based super-alloys. Through the recent RTI acquisition, Alcoa gained 3D printing capabilities in titanium, other specialty metals and plastics for the aerospace, oil and gas and medical markets. This expansion positions Alcoa to industrialize its advanced 3D printing capabilities across these and other manufacturing facilities.
About RTI's 3D printing capabilities: RTI > 3DPrinting
From the Alcoa/Arcam webinar coming up on April 21st - Alcoa - Capturing the growing demand of Additive Manufacturing parts in Aerospace, the text indicates that Arcam machines have been used within Alcoa. Arcam also appears to be very much in Alcoa's future.
Key Take-Aways
Design freedoms afforded by additive manufacturing
The cost & weight savings AM parts can deliver to the aerospace market
Thru-put and speed considerations for production parts
Highlights of applications of Electron Beam Melting at Alcoa
This looks like the patent: Methods for producing forged products and other worked products. It may not be the correct or only patent involved. There are five other patents referenced and included. "Each of these applications is incorporated by reference in their entirety herein."
After a VERY brief examination, I don't believe that the AM method is specifically identified. It looks like it's a method to combine AM items with other components. It doesn't look like Alcoa is identifying a new AM method of their own but is describing a process to incorporate AM components with other components to make a larger item. This looks like additive manufacturing where it's needed/desired and conventional manufacturing where it's not to produce a single part made up of two or more components.
Alcoa Expands R&D Center to Deepen Additive Manufacturing Capabilities - September 3, 2015.
Selected portions of the press release:
Demonstrating this integrated strategy, the Company today unveiled its Ampliforge™ process, a technique combining advanced materials, designs and additive and traditional manufacturing processes. Using the Ampliforge™ process, Alcoa designs and 3D-prints a near complete part, then treats it using a traditional manufacturing process, such as forging. The Company has shown that the process can enhance the properties of 3D-printed parts, such as increasing toughness and strength, versus parts made solely by additive manufacturing. Further, the Ampliforge™ process significantly reduces material input and simplifies production relative to traditional forging processes. Alcoa is piloting the technique in Pittsburgh and Cleveland.
Combination of Process and Design: Alcoa will further its development of advanced 3D-printing design and manufacturing techniques—such as Alcoa’s Ampliforge™ process—to improve production speeds, reduce costs, and achieve geometries not possible through traditional methods. Direct production of 3D-printed metal parts represents a new way to manufacture aerospace components and requires a new suite of innovative design tools to realize its full potential. By connecting our materials scientists with our manufacturing experts, we enable a rapid development feedback loop to inform new software tools and processes that take full advantage of additive capabilities.
This expansion of the Alcoa Technical Center builds on Alcoa’s additive manufacturing capabilities in California, Georgia, Michigan, Pennsylvania and Texas. The Company has been creating 3D-printed tools, molds and prototypes for the past 20 years and owns and operates one of the world’s largest HIP (Hot Isostatic Pressing) complexes in aerospace, a technology that strengthens the metallic structures of traditional and additive manufactured parts made of titanium and nickel based super-alloys. Through the recent RTI acquisition, Alcoa gained 3D printing capabilities in titanium, other specialty metals and plastics for the aerospace, oil and gas and medical markets. This expansion positions Alcoa to industrialize its advanced 3D printing capabilities across these and other manufacturing facilities.
About RTI's 3D printing capabilities: RTI > 3DPrinting
From the Alcoa/Arcam webinar coming up on April 21st - Alcoa - Capturing the growing demand of Additive Manufacturing parts in Aerospace, the text indicates that Arcam machines have been used within Alcoa. Arcam also appears to be very much in Alcoa's future.
Key Take-Aways
Design freedoms afforded by additive manufacturing
The cost & weight savings AM parts can deliver to the aerospace market
Thru-put and speed considerations for production parts
Highlights of applications of Electron Beam Melting at Alcoa
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