Rail transport techniques producer Alstom is utilizing Wire Arc Additive Manufacturing (WAAM) to provide automobile parts ‘at brief discover.’
The corporate is leveraging WAAM know-how from GEFERTEC, having labored with the German machine provider since 2020.
5 years in the past, GEFERTEC produced the primary wheelset bearing cowl for Alstom utilizing WAAM know-how, with Alstom returning to make use of the corporate’s additive manufacturing companies lately to provide a yaw damper for an older rail automobile. Initially a forged metal part, the yaw damper is situated between the bogie and automobile physique, serving to to make sure automobile stability at excessive speeds and on curvy routes. Reproducing this half utilizing metal casting would have taken too lengthy and been too pricey, so Alstom turned to GEFERTEC.
Initially, GEFERTEC’s group carried out a feasibility examine primarily based on the fabric and geometry information, earlier than deciding on the fabric, defining the instrument paths and establishing the manufacturing parameters. Current design information needed to be transformed right into a format appropriate for the additive course of, with machining allowances additionally having to be digitally built-in, however GEFERTEC was in a position to manufacture the half in a well timed method.
For the reason that dampers are uncovered to excessive masses and should adhere to stringent rules, an in depth testing course of – inclusive of static and dynamic testing – ensued. Inside 100 days of the feasibility examine commencing, nevertheless, the additively manufactured half was delivered to Alstom.
“The transparency throughout undertaking execution and within the analysis of checks was convincing,” stated Dr.-Ing. Uwe Jurdeczka, Head of the Modern Manufacturing Applied sciences Group at Alstom. “Sharing all outcomes turned out to be uncomplicated. Sooner or later, it is smart to design parts for additive manufacturing proper from the beginning, particularly in view of rail sector traits like light-weight building and purposeful integration.”