Intech and HAL develop first-in-india 3D Printed Aero-Engine part using Superalloy CM 247LC

Intech and HAL develop 3D Printed Aero-Engine part using Superalloy CM 247LC
Aditya Chandavarkar

Aditya Chandavarkar is a established entrepreneur with business interests in manufacturing, innovative technology and consulting. He is the co-founder of CNT Expositions and Services (acronym for Catalysing New Technologies), which was subsequently formed by the acquisition of Inkjet Forum India – a leading knowledge sharing platform for inkjet printing technology founded by him. At Inkjet Forum India, Aditya was single handedly responsible for conceptualizing and organizing conferences and educations programs, in the area of digital textile printing and industrial inkjet.

Intech Additive Solutions & Hindustan Aeronautics Limited (HAL) are the first in India to develop a 3D Printed Aero-Engine part using Superalloy CM 247LC

Hindustan Aeronautics Limited (HAL), AERDC Division, has proactively worked with Intech Additive Solutions to manufacture the Gas Generator – Nozzle Guide Vane (GG-NGV) using 3D printing. Collaborations in data sharing, powder qualification, testing capabilities, and design feasibility studies between the teams of the respective organizations have paved the way in successfully manufacturing the part.

The Gas Generator – Nozzle Guide Vane (GG-NGV) is manufactured using Super-Alloy CM 247LC, a cast nickel-base superalloy with low carbon content.

GG-NGV printed on iFusion LF1 using superalloy CM 247LC (320mmx70mm)
GG-NGV printed on iFusion LF1 using superalloy CM 247LC (320mmx70mm)

Parts with CM 247LC have traditionally been manufactured using investment castings. This process involves many complex steps, making it expensive and time-consuming.

Additive Manufacturing is the perfect fit for making such components as it has no geometry limitations. In research and design, the required quantity of parts is low, coupled with the necessity of iterative improvements. Additive Manufacturing is ideal in these situations as it reduces cost and has the added benefit of enabling the on-demand printing of parts.

CM 247LC is, however, crack-prone, and previous attempts across the world to print parts with this material have not entirely been successful. For the most part, these efforts have been limited to R&D initiatives with no proven manufacturability.

GG-NGV printed on iFusion LF1 using superalloy CM 247LC (320mmx70mm)
GG-NGV printed on iFusion LF1 using superalloy CM 247LC (320mmx70mm)

With its vast experience in qualifying materials, Intech Additive Solutions decided to take up this challenge head-on. Intech’s home-grown software, AMOptoMet, generates parameters virtually at just the click of a mouse. With HAL’s expertise in material properties combined with Intech’s experience in developing reliable parameters with AMOptoMet, the powder was successfully qualified for Additive Manufacturing. Intech printed this rather large part (about 320 mm) using the LF1 System (launched earlier this year), which has a large build envelope of 450x450x450 mm. This 3D-printed aero-engine component can operate at high temperatures and function at a very high RPM.

“We are setting new Additive Manufacturing industry benchmarks from India. What would take weeks or months now takes minutes or hours using our software to parameterise custom alloys for critical applications. We are demonstrating through real parts how AM can reduce inventory and pushing the just-in-time concept in Aerospace applications”, says Pradeep Nair, Vice President-Hardware Sales at Intech Additive Solutions.

“The Metal 3D printed component manufactured using CM-247 alloy is a great headway for the design, development and production of aero-engine components. We are proud to be associated with Intech Additive Solutions for successfully manufacturing the ‘GG-NGV’ aero engine part, especially using superalloy ‘CM 247LC’. The collaboration with Intech Additive Solutions for manufacturing GG NGV using CM-247 LC for aero engine applications promotes the principles of ‘Make in India’ and Aatmanirbhar Bharat Abhiyan”, says Dr. T.R. Rajanna, CD (AERDC-HAL).

About Intech Additive Solutions:

Intech Additive Solutions, a leading solutions provider in metal AM systems and AM Software, is the first Indian OEM successful in developing and supplying 3D metal printers based on Laser Powder Bed Fusion technology (LPBF) for industrial manufacturing.

Intech is among the few manufacturers globally to integrate its metal printers with its in-house build processing software – AMBuilder and an additional software tool, AMOptoMet, for parameter optimization. Intech’s printers, combined with these two software packages, provide users with an end-to-end metal AM solution in addition to local after-sales services.

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Aditya Chandavarkar

Aditya Chandavarkar is a established entrepreneur with business interests in manufacturing, innovative technology and consulting. He is the co-founder of CNT Expositions and Services (acronym for Catalysing New Technologies), which was subsequently formed by the acquisition of Inkjet Forum India – a leading knowledge sharing platform for inkjet printing technology founded by him. At Inkjet Forum India, Aditya was single handedly responsible for conceptualizing and organizing conferences and educations programs, in the area of digital textile printing and industrial inkjet.