20.11.17 Can 3D print technology be used for repair and reconditioning, reducing the number of scrapped maritime parts?
That is exactly what PJ Diesel and a group of partners has set out to assess in a new project exploring the opportunity space of 3D print across the maritime supply chain from original equipment manufacturer, to end user. In collaboration with DNV GL, DTU, Dycomet, FORCE Technology, KBB, Maersk Drilling, and Thürmer Tools, PJ Diesel Engineering has identified a number of suitable test parts that can be repaired with the use of laser cladding and cold spray 3D print technology. Besides exploring maritime appliance of 3D print technology, the presence of the entire supply chain is in itself a first in a project within this field.
With the project, the group of partners has taken an important step towards exploring how emerging technologies can contribute to a more energy efficient and sustainable maritime industry. Not only can scrapping of materials be reduced, but lead time can be minimized, reducing expensive down time. Working with the whole value chain and utilizing the latest technology with a specific focus on sustainability makes this project unique.
“Being able to gather the whole maritime value chain around an additive manufacturing project like this is to my knowledge a first – many industry leaders talk about collaboration but here we have a real-world example” – states Rasmus Elsborg-Jensen of PJ Diesel.
Laser Cladding is an additive manufacturing technique in which powder is fed into a melt pool created by a laser. The laser is scanned across the surface to add material one layer at a time. A CAD solid model of the part is used to create the code to guide the laser. This technology has been around for some time now, but it is continuously improved and developed. The technology being applied in this project is brand new, with 6 powder feeders allowing for cladding quality that does not depend on direction of head movement. DNV GL will oversee the processes, and take part in quality assurance and verification.
With cold spray, a metal powder is sprayed onto a component below the metals melting point, hence “cold” spray. The technology allows a service provider or supplier to rebuild or strengthen a part with a metal alloy, instead of replacing it with a new. There are two types of cold spray; high pressure and low pressure. High pressure cold spray can be used with harder metals, but has to be performed in a chamber. The low pressure cold spray consists of a portable kit that can be used manually, which enables on-site repair of parts, making the technology particularly relevant for e.g. oil rigs and vessels.
The project is one of four Green Ship of the Future projects exploring different aspects of 3D print technology. The other projects explore on-board print, large scale 3D print and 4D print. In addition to their individual focus areas, the four projects also deal with 3D print and the impact on the maritime supply chain.
The project is financed by the Danish Maritime Fund and expected to end ultimo 2017.
For more information about the project, contact Project Manager, PJ Diesel Engineering Vanja Wylie at email@example.com or head of secretariat Green Ship of the Future Anne Katrine Bjerregaard firstname.lastname@example.org
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PJ Diesel Engineering
PJ Diesel Engineering A/S was established in 1978 in Copenhagen with focus on sustainable recondition and repair of maritime components. Today the family owned company is represented in more than 7 countries and are more than ever focused in bringing down emissions by utilizing the latest technologies in their repair and reconditioning procedures.
PJ Diesel offer reconditioning of used or damaged components, as well as a comprehensive scope of standard replacement parts for turbochargers, fuel injection equipment, governors. They also recondition engine components, e.g. cylinder covers, cylinder liners, pistons, connecting rods and exhaust valve cages.
PJ Diesel Engineering A/S is an authorized representative for many leading OEMs like Woodward, Mitsubishi, KBB and RE governors.
Green Ship of the Future
Green Ship of The Future (GSF) is a public private partnership with 50 members from across the maritime industry from shipowners, OEMs and suppliers to class, authorities and research institutions. Green Ship of the future is working towards emission free maritime transport, is ambitious in the exploration and use of new technologies and enables innovation across maritime value chains. Through collaborative innovation across the maritime supply chain, GSF members explore, develop and demonstrate green technology in ambitious projects with the overall goal of making shipping and the maritime industry more innovative, energy efficient and sustainable. Green Ship of the Future is funded by the members, with donations from The Danish Maritime Fund, the Orient’s Fund and the Lauritzen Foundation.