New inexperienced fuels and a purpose of accelerating efficiency can make it enticing to 3D print parts of the massive cargo ship engines.
The giant marine engines of the world’s cargo ships are an essential focus space within the maritime business’s efforts to grow to be more sustainable. This additionally applies to the person parts of the engine, which should be constantly optimized to be able to meet the long run necessities of a decrease and greener gasoline consumption.
An important part on this context is the injection nozzle, which injects gasoline into the engine, the place it’s combined with oxygen to make sure optimum combustion.
In a collaborative undertaking between DTU and MAN Energy Solutions, a younger researcher has carried out an intensive investigation into whether or not it could possibly be advantageous to make a 3D-printed injection nozzle.
“At MAN Energy Solutions, we’ve long been aware that 3D-printed metal can provide us with some opportunities to design important parts of our ship engines that were not previously possible. This made a collaboration with DTU on exploring the potential an obvious choice,” says Peter Hagen, mechanical engineer at MAN Energy Solutions.
Broad evaluation of 3D printing’s prospects
Postdoc Thomas Dahmen from DTU Mechanical Engineering carried out the examine, the place he started by finishing up a Quality Deployment Function evaluation for 3D printing. 3D-QFD is an evaluation mannequin used to offer an outline of the worth 3D printing can add to a product as an entire.
“By applying the model and combining it with technical insight into both 3D printing methods and fuel injection, I have created a modular kit of how 3D-printed nozzles can be designed to increase engine performance and product lifetime,” says Thomas Dahmen.
The enchancment of the injection nozzle was based mostly on the truth that a greater gasoline circulate could possibly be achieved with a barely totally different—and more curved—design. In this fashion, the brand new nozzle design contributes to improved engine combustion. Initial trials additionally counsel that the nozzle might doubtlessly assist cut back NOx emissions from the engine, however additional research will likely be required to reveal such an impact.
Comparing two totally different 3D printing strategies
The new 3D-printed injection nozzle confirmed such promising leads to the DTU laboratory that it was subsequently examined on MAN Energy Solutions’ full-scale check engine at Research Centre Copenhagen.
“The test went well, and we look forward to doing a long-run test next,” says Peter Hagen and continues:
“Thomas’ thorough investigation has given us a fantastic basis for moving forward with 3D printing of metal components for marine engines. I’m quite sure we’ll see them in real engines soon.”
Peter Hagen stresses that the collaboration with DTU on continued optimization of marine engines will proceed sooner or later.
In his complete evaluation, along with wanting on the nozzle design, Thomas Dahmen additionally in contrast the professionals and cons of two totally different 3D printing strategies—Laser Powder Bed Fusion and Binder Jetting— together with utilizing totally different kinds of supplies for the nozzles.
“This part of the analyses highlighted the suitability of Binder Jetting for intricate flow-related nozzle features and special high-temperature materials which would be impossible to realize with other manufacturing processes,” says Thomas Dahmen.
Technical University of Denmark
3D-printed engine parts can make cargo ships more eco-friendly (2022, January 12)
retrieved 12 January 2022
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