Alcoa operates 3D printed metal powder production plant

Alcoa announced that it has started running its most advanced 3D printed metal powder production plant. The plant, located at the Alcoa Technology Center, the world’s most advanced metal research center near Pittsburgh, Pennsylvania, will produce optimized patented titanium, nickel and aluminum alloy powders for 3D printing of aerospace components.

“Alcoa is aggressively developing additive manufacturing and is keenly aware of the key input material – metal powder,” said Klaus Kleinfeld, Chairman and CEO of Alcoa. “We are integrating our expertise in metallurgy, manufacturing, design and product certification. Expertise to promote the potential of current 3D printing technologies in aerospace and other high-growth markets."

The amount of metal powder used for 3D printing of durable and high quality aerospace parts is limited. Through this expansion announced in September 2015, Alcoa will develop special performance materials for 3D printing of high-performance components.

Alcoa has deep expertise in the development of metal alloys and has invented most of the current aerospace aluminum alloys. In addition, Alcoa has a 100-year history in the production of metallic aluminum powder, which is mainly used in rocket fuel, paint and other products.

In the second half of 2016, Arconic will be separated from the traditional business of Alcoa, which will be part of Arconic. Alcoa invested $60 million in California, Georgia, Pennsylvania, and Texas to enhance its 3D printing capabilities. The construction of this metal powder plant is part of this investment.

In addition to producing powders, Alcoa also focuses on and advances a range of additive manufacturing technologies, including its recently introduced AmpliforgeTM process, a hybrid technology that combines additive manufacturing with traditional manufacturing.

In the AmpliforgeTM process, Alcoa designed and 3D-printed near-net shape parts and then processed them using conventional manufacturing processes such as forging. This process can enhance the performance of 3D printed parts, and can increase toughness and strength compared to simply using additive manufacturing processes, and significantly reduce material investment. Alcoa is piloting this technology in Pittsburgh and Cleveland. (Northern Institute of Science and Technology Information, Huang Qiushi)