China3D printingNet July 23, high-performance sports car manufacturer Porsche has partnered with machine tool manufacturer TRUMPF and auto parts company MAHLE to provide engines for its flagship 911 super sports car3D printingpiston.
Using laser metal fusion (LMF)3D printingTechnology, car manufacturers’ engineers have been able to optimize the structure of car parts under load. AI-led additive manufacturing technology also enables Porsche to integrate cooling ducts into the “top cover” of the component. Compared with mass-produced pistons, these features not only reduce the weight of the piston by 10%, but also increase the horsepower of the 30 BHP engine for Porsche.
Frank Ickinger from Porsche Advanced Driving Development explained: “With new, lighter pistons, we can increase engine speed, reduce temperature load on the pistons and optimize combustion. It is possible for turbocharged engines to obtain up to 30 PS of power while increasing efficiency.”
Additive Manufacturing of Porsche Pistons
use3D printingInstead of traditional production methods to manufacture pistons, Porsche can focus on the use of materials in the areas where the parts are subject to the greatest external force. This technology makes the piston much lighter than current supercars and generates 30 horsepower from its 3.8-liter twin-turbocharged engine, raising it to 730 BHP.
” 3D printingThis allows us to build projects in a bionic manner and produce extremely lightweight and high-strength components, which now help us to reduce a lot of weight when we design pistons. “MAHLE Advanced Enterprise EngineeringProject leader Dominik Abele explained, “We can now run the engine at a higher RPM, which will generate more power.”
Emphasis is placed on the outer shell or “skirt” of the piston, and the point where it meets the “connecting rod” of the part, called a “pinball”.Integrate cooling channels into components, thereby reducingThese areasTemperature and improve the overall efficiency of the engine. In addition, using AI to optimize the shape and basic topology of the piston can minimize the need for support materials. Therefore, at the later stage of this process, only the hole of the part “wrist needle” needs to be removed.
Porsche produced six prototype pistons using high-purity M174+ aluminum alloy powder manufactured in-house by MAHLE, and used the TRUMPF 5000 system to perform3D printing.During a total of 12 hours, laser melting is used3D printingThe technology constructs 1200 layers of parts and shapes the powder into the final product. Then, the printed piston undergoes the same preparation steps as a conventional piston: machining, measurement and testing.
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The piston passed the preliminary verification test” alt=” Porsche’s
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The piston passed the preliminary verification test” width=”620″ height=”350″ />
Porsche3D printingThe piston passed the preliminary verification test. The picture comes from Porsche.
Verification of newly developed additive parts
After the components are configured, they enter the Porsche standard “pulse” test to check the wall thickness. These parts have also undergone “tear” inspections to ensure that their marbles will not harden under load. 3D printingNot only has the piston passed, but further bench evaluations will now continue, which are designed to measure its long-term durability. To test its consistency, these tests included 135 hours of full load operation at various speeds and 25 hours of drag load.
“The results are out and all the pistons have passed the test. Next, a benchmark test, which is a 200-hour endurance test under the worst conditions, is required,” added Ulrich Kunzmann, head of MAHLE prototype manufacturing. “Positive results confirm3D printingThe great potential of, especially in high performance, small batches and limited runs, and prototype development. “
Although testing is still ongoing, Porsche has not yet committed to3D printingThe components are installed in its commercial vehicle. Nevertheless, the company did say that it has already played a safety role in the design of the piston, and the part can still be further optimized to improve performance. “We always make sure that we make mistakes. Our simulation results show that the weight of each piston can be saved by as much as 20%.
Then the torsional vibration damper can be made smaller, allowing the engine to spin more freely. The increased thermal resistance due to the decrease in temperature also allows for higher combustion pressures and even earlier ignition timing, both of which increase power and efficiency. “
therefore,3D printingIt is still an important part of the company’s path forward and is excited about the technology’s potential in the industry. I believe that additive manufacturing will become an important part of automotive R&D and production. “
3D printingTechnology (as shown in the picture) to produce pistons with enhanced performance” alt=”Porsche uses TRUMPF’s LMF 3D printingTechnology (as shown in the picture) to produce pistons with enhanced performance” width=”620″ height=”350″ />
Porsche uses TRUMPF’s LMF 3D printingTechnology (as shown in the picture) to produce pistons with enhanced performance. The picture comes from Porsche.
Additive manufacturing in the automotive industry
Porsche did not promise to use its newly developed pistons in production cars, but in the past it has3D printingA series of parts and components for end use. For example, in February 2018, the supercar manufacturer began printing spare parts for its rare and classic cars.It was subsequently announced earlier this year that it will carry out3D printingCustomized bucket seats for 40 prototypes for European racing tracks.
Other car companies have also benefited from additive manufacturing, such as the startup Czinger, which plans to launch its first model in 20213D printingSupercar 21C.use3D printing, This car worth 1.7 million US dollars will reduce weight and cost. Compared with traditional production methods, it has greater benefits and benefits from reduced manufacturing time.
At the same time, the additive manufacturing consulting company APWORKS has provided the latest Bugatti Chiron supercar3D printingMetal parts. The tailpipe assembly is made of titanium to make it lighter and more resistant to high temperatures.
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