Velo3D qualifies new superalloy for use in Sapphire AM machines

January 6, 2022

The combustor liner is made using Amperprint 0233 Haynes 282 powder from Höganäs. The part is shown as additively manufactured with no supports (Courtesy Velo3D)

Velo3D, Inc, headquartered in Campbell, California, USA, has qualified the nickel-base superalloy powder Amperprint® 0233 Haynes® 282® for use in its Sapphire® range of metal Additive Manufacturing machines. The powder was produced by Höganäs AB under license from Haynes International, Inc, and is designed for high creep strength, thermal stability, weldability, and fabricability uncommon in other alloys. The material is said to be ideal for high-temperature structural applications like energy generation, gas turbines, and space launch vehicles to build parts like heat exchangers, combustors, nozzles, combustion liners, rocket engines, and shrouded impellers.

The first Sapphire AM machine utilising the Amperprint 0233 Haynes 282 powder will be operated by Duncan Machine Products (DMP), a contract manufacturer based in Duncan, Oklahoma, USA. The machine will be the seventh in DMP’s fleet of Velo3D Sapphire AM machines.

“Our goal at Velo3D is to enable engineers to build the parts they want without compromising on the design or quality,” commented Benny Buller, Velo3D CEO and founder. “Qualifying new powdered metals, like Amperprint 0233 Haynes 282, for use in our end-to-end solution further expands what’s possible with our Additive Manufacturing technology. Our partners at Höganäs provide materials of the highest quality and I look forward to seeing what our customers build using this amazing alloy.”

Cut-away view of the combustor liner. The part features 23,000 unique holes for optimised air-to-fuel ratios and internal channels for regenerative cooling (Courtesy Velo3D)

Powdered nickel-base superalloys, such as Amperprint 0233 Haynes 282, are often used to additively manufacture parts for use in high-temperature applications due to the alloy’s resistance to cracking and its ability to operate at near-melting-point temperatures. This tolerance allows parts produced with the alloy to be used in vacuum, plasma, and other demanding applications. Its high weldability makes the powder ideal for parts in larger systems because of its ability to be welded to other components.

Jerome Stanley, Höganäs Director of Global Sales, Customization Technologies, stated, “It’s inspiring to see what engineers have been able to build using metal powders from Höganäs and Velo3D’s support-free Additive Manufacturing process. The first parts printed using our Amperprint 0233 Haynes 282 powder are impressive, and I believe customers are only scratching the surface of what is possible with this superalloy. The powder, combined with Velo3D’s end-to-end solution metal AM solution, is an extremely effective combination for consolidating parts into monolithic structures to eliminate coefficient of thermal expansion in large, high-performance systems.”

Velo3D states that it is one of the first AM technology companies to offer Amperprint 0233 Haynes 282 powder to its customers. Many of Velo3D’s customers use its end-to-end solution to produce parts for use in aviation, energy, oil and gas, space, and other high-performance applications, making the powder a good fit for Velo3D’s portfolio. In addition to Amperprint 0233 Haynes 282 powder, metal powders qualified to be additively manufactured with Velo3D’s technology include Hastelloy X®, Inconel 718, aluminium F357, Ti 6Al-4V Grade 5, and several other materials.

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