Bodycote Powdermet^® technologies

Powdermet® 3D Printing

Powdermet® 3D Printing technology combines building of three-dimensional parts layer-by-layer based on digital models with Bodycote post-build processes of heat treatment and hot isostatic pressing. This additive manufacturing technique allows the flexibility of creating complex components with unique material properties quickly and less costly compared to traditional subtractive methods.

Advantages of Powdermet® 3D Printing:

• Enhances uniform mechanical properties
• Achieves 100% powder consolidation
• Eliminates porosity
• Reduces possible risks from premature failure
• Imparts isotropic properties

Powdermet® Selective Surface Net Shape (SSNS)

Powdermet® SSNS technology produces components which require minimal post-process machining and retain their finished machined tolerances. Powdermet® SSNS can be used to produce components that would be cost-prohibitive if manufactured by other means.

Benefits of Powdermet® SSNS:

• Freedom in design
• Reduces material usage significantly compared to forged components
• Eliminates costly machining operations
• Shortens delivery lead times
• Minimises finishing processes to mating or critical design surfaces only

Certain environments or applications benefit from the use of very high strength alloys. These alloys are easily incorporated into SSNS technology unlike competing casting processes. Selective surface net shape parts made from optimal alloy composition offer higher performance, extended life and repeatability in volume manufacturing. Powdermet® SSNS technology has been flight tested on aerospace applications and is well suited for oil and gas applications.

Oil & Gas

Oil & gas operations require specialised equipment that must be reliable, cost-effective and safe to the environment. Powdermet® components provide integrated, highly complex parts with shorter lead times. Unlike conventionally forged billets and preforms, machining and welding are minimal. In subsea manifold systems, subcontract welding has been reduced by up to 80%.

Powdermet® 3D printing technology, particularly in high pressure, high temperature sour environments, reduces the cost of expensive materials and extends component service life. The homogeneous microstructure in Powdermet® hybrid technology increases wear and corrosion resistance in components required to meet the increasingly stringent demands of the offshore industry. Multiple large and complex components can be combined and produced as a single piece in one-off or full production operation - a cost-effective manufacturing route. Net shape features at key locations within a component eliminate the need for machining in difficult-to-access areas, enhancing performance and component life through material optimisation in critical areas.

Power Generation

The power generation industry is constantly working to improve the efficiency of turbines and looking at new ways to manufacture components. For example, Powdermet® technology has successfully been used to produce steam chest parts in steam turbines, which have intricate internal cavities. It is the only manufacturing technique available to achieve complex internal profiles. Other application examples include rotors, turbine discs, diaphragms, valve bodies and steam generator components.