Additive Manufacturing for Large Products

Abstract

This thesis researches the possibility and feasibility of applying additive manufacturing technology in the manufacturing of propellers. The thesis concerns the production at the foundry Oshaug Metall AS. Their products consist of propellers and other large products cast in Nickel-Aluminium Bronze. This report looks at three approaches and applications for additive manufacturing at the foundry. These are additively manufactured pattern, sand mold and end metal parts. The available \emph{State of the Art} systems for the three approaches are listed and the systems suitability is discussed. The systems that meet the stated criteria are selected and further discussion on the advantages and disadvantages of the additive manufacturing approach to the application are carried out for the three respective applications. An experiment was carried out on a scaled propeller blade to measure the geometrical accuracy and surface quality of a 3D-printed pattern. The report is concluded with the conclusion to the stated task and recommendations for further work.