This text was initially printed in VoxelMatters’ Metallic AM Focus 2025 eBook. The total version might be discovered right here.
Within the maritime trade, notably within the shipbuilding section, materials selection is a essential consideration. Whereas in industries like aerospace, minimal weight and high-temperature resistance are a prime precedence, within the maritime sector, corrosion resistance and sturdiness are probably the most important materials properties. It makes good sense: elements on a ship should have the ability to face up to the tough surroundings at sea, together with the corrosive nature of sea water, whereas additionally providing structural integrity and a protracted lifespan.
For these causes, the maritime trade has gravitated in the direction of a comparatively small number of metallic sorts, together with metal (ship hulls are constructed from metal, as an example), aluminum (used for superstructures and non-structural elements to maximise gas effectivity), Inconel (used for propeller blades and scrubbers) and different superalloys. Within the rising maritime AM subsegment, a small variety of particular alloy sorts have risen to the highest and chief amongst them are copper–nickel alloys (CuNi).
CuNi alloys are already effectively established within the maritime trade. The metals, identified for his or her glorious corrosion resistance and low macrofouling charges, have varied purposes in offshore, naval and shipbuilding segments, together with desalination programs, piping, warmth exchangers, condensers and extra. Whereas most CuNi components in maritime are manufactured utilizing extra conventional strategies like casting, additive manufacturing is more and more changing into a viable choice as firms within the AM trade develop and validate CuNi for varied metallic 3D printing processes. That is notably vital contemplating that solid CuNi alloys might be tormented by challenges like cracks and porosity, which necessitates rework, in the end driving up prices and lead occasions.
With the ability to additively manufacture CuNi components affords shipbuilding and naval organizations a number of advantages, together with unlocking extra fast manufacturing occasions (eliminating the necessity for tooling), lowering reliance on giant stock shares, simplifying provide chains and manufacturing extra effectively designed elements. On prime of that, AM permits extra sustainable practices by means of the minimization of fabric waste and extra localized manufacturing, which reduces emissions related to logistics. Applied sciences like directed vitality deposition (DED) are additionally making it doable to restore current elements additively, which has advantages in terms of sustainability (extending the lifespan of enormous components) and value.
Throughout the AM trade, solely a small variety of firms presently provide copper-nickel alloy supplies. It’s value stating, nevertheless, that although the group is small, it’s rising, with new CuNi merchandise being launched and validated up to now 12 months. This latest development simply goes to indicate how the metallic AM trade is recognizing the large potential of maritime as an AM adopter.
The first CuNi alloy developed particularly for maritime additive manufacturing was launched in 2022 by 3D Programs. The fabric, CuNi30, was developed for the corporate’s DMP Flex 350 platform by means of a collaboration with HII’s Newport Information Shipbuilding division. The fabric reportedly ends in components with superior density and mechanical properties in comparison with solid components—all with out the necessity for tooling—and demonstrates stability over a broad vary of temperatures (from 400 °C to -270°C). These properties make CuNi30 appropriate for a variety of maritime (and adjoining) purposes, like ship pipe fittings, valves and pumps; off-shore oil and gasoline elements; chemical and nuclear tools; and even cryogenic programs.
The introduction of the fabric enabled Newport Information Shipbuilding to take advantage of the advantages of LPBF for its low-volume, high-mix half necessities. On the time of the fabric launch, the tip consumer anticipated a dramatic 75% discount in lead occasions and decrease stock prices in comparison with their typical casting workflows.
For the reason that launch of 3D Programs’ licensed CuNi30, German 3D printing chief EOS has additionally developed its personal CuNi30 powder for LBPF, with a nickel content material of 28–32%, and small quantities of niobium, iron and manganese. The copper-nickel alloy, which launched commercially in early 2024, affords a variety of properties appropriate for maritime purposes, resembling glorious power with as much as 700 MPa in heat-treated horizontal builds, and ductility with round 510 MPa UTS and greater than 20% elongation.
The alloy was developed and validated in cooperation with Philips Federal and Austal USA for the Submarine Industrial Base (SIB). Particularly, EOS developed the fabric with the goal of “assuaging provide chain pressures” on conventional solid elements for the two+1 Columbia and Virginia Class submarine platforms for the US Navy. The AM-grade materials conforms to UNS C96400 specs in ASTM B369-09 and affords the identical stage of corrosion resistance as solid CuNi elements with out the manufacturing woes. By way of utility, EOS’ CuNi30 is right for a variety of maritime elements, together with pumps, impellers, submarine seawater consumption valves, high-pressure piping and propulsion {hardware}.
In 2024, ADDMAN Group, by means of its Harbec enterprise unit, entered right into a partnership with the US Navy to qualify CuNi elements for submarines. This qualification effort is in the end geared toward establishing AM as a viable manufacturing technique for CuNi components in an effort to speed up procurement cycles and enhance general half high quality. For the US Navy particularly, 3D printed CuNi may meet its “2+1” submarine manufacturing targets.
Within the final 5 months, at the very least three new efforts to qualify copper-nickel alloys for additive manufacturing have arisen with the goal of furthering AM purposes within the maritime and protection (particularly naval) sectors. Australia-based AML3D, a specialist in Wire Additive Manufacturing (WAM) introduced in Might that it had signed a $1.01 million buy order with BlueForge Alliance, a nonprofit integrator that helps the US Navy’s Submarine Industrial Base, to develop and qualify CuNi alloys for protection purposes. This follows a profitable characterization of a CuNi alloy in 2023, which was a part of a US Navy submarine qualification program.
In the identical month, UK-based metallic AM firm Renishaw revealed it had teamed up with Austrian metallic powder producer Metalpine to develop and qualify CuNi powders to allow a “main European naval drive” to provide alternative components in-house. Particularly, the companions developed course of parameters for CuNi 10 (which consists of 90% copper and 10% nickel) and CuNi 30 (70% copper, 30% nickel).
“With these exact settings we’ve overcome the fabric’s challenges, guaranteeing high-quality, sturdy components that may face up to harsh marine environments,” mentioned Alex Garcia, AM Design and Functions Engineer at Renishaw. “This optimization enhances half power and longevity and ensures constant outcomes, permitting our naval buyer to fabricate components that carry out reliably below powerful situations.”
Extra just lately, American metallic AM firm Velo3D introduced the event and qualification of a CuNi alloy for its Sapphire 3D printer sequence. The event, formalized by means of a $6 million contract, will assist the US Navy Maritime Industrial Base within the restore of essential ship buildings and elements. Notably, Velo3D says this contract will make it the primary American OEM to qualify CuNi for its domestically developed 3D printers, together with the large-format Sapphire XC 3D printer.
The CuNi growth course of is being led by Velo3D’s crew in Fremont, California, which is able to develop course of parameters for a powder provided by a home, brazenly sourced metallic powder supplier (a crucial consideration in an effort to preserve provide chain independence for the US Navy.”
In the end, the event of CuNi alloys for AM processes and platforms will solely profit finish customers from the maritime and naval sectors, as they can’t solely leverage the advantageous properties of the fabric, but in addition the inherent property of AM, together with design freedom, manufacturing agility and materials effectivity.
