Oak Ridge National Laboratory researchers (ORNL) recently used large-scale additive manufacturing with metal to produce a full-strength steel component for a wind turbine, proving the technique as a viable alternative to conventional welding approaches.
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Wind energy adoption in the United States is heavily reliant on the ability of industry to produce huge, complicated structures. When compared to traditional processes, additive manufacturing, or 3D printing, has the potential to cut costs and boost production efficiency.
Polymer and metal-based 3D printing technologies were used in a demonstration to create the turbine’s skeleton node, which functions as a load-bearing junction between structural beams. The study team analyzed performance and overall manufacturing costs and concluded that, while near-term prices for 3D printing were equivalent to welding, long-term estimated future costs proved beneficial.
“Metal additive enables for innovative designs and lightweight components that would not be possible with standard methods,” stated Brian Post of ORNL. “With this method, large-scale recyclable metallic wind turbine structures might be rapidly printed.”
About Oak Ridge National Laboratory (ORNL)
Oak Ridge National Laboratory delivers scientific discoveries and technical breakthroughs needed to realize solutions in energy and national security and provide economic benefit to the nation. We address national needs through impactful research and world-leading research centers. Our wide range of partnerships with other US Department of Energy laboratories and programs, universities, and industry allows us to pair our strengths with others for outstanding contributions to science.
ORNL researchers apply unique facilities, sophisticated tools, and signature strengths in neutron science, high-performance computing, advanced materials, biology and environmental science, nuclear science and engineering, isotopes, and national security research to benefit science and society, making it possible for us to:
- Advance understanding, design, and use of new materials and chemical processes
- Reveal unmatched insights through computing and data
- Ensure safe, clean nuclear power and secure nuclear materials
- Produce rare isotopes for medicine, industry, security, research, and space exploration
- Increase and exploit understanding of biological and environmental systems, from genes to ecosystems
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