Alcoa (Pittsburgh, Pa.; www.alcoa.com) has opened its state-of-the-art, 3-D printing metal powder production facility. Located at the Alcoa Technology Center, the world’s largest light metals research center, the Company will produce proprietary titanium, nickel and aluminum powders optimized for 3-D printed aerospace parts. Alcoa also has invested in a range of technologies to further develop additive processes, product design and qualification.
“Alcoa is forging a leadership path in additive manufacturing with a sharp focus on the critical input material—metal powders,” said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. “We are combining our expertise in metallurgy, manufacturing, design and product qualification to push beyond the possibilities of today’s 3-D printing technologies for aerospace and other growth markets.”
Metal powders used for 3-D printing durable, high-quality aerospace parts are available in limited quantities. Through this expansion, announced in September 2015, Alcoa will develop materials with the specific properties needed to 3D print high-performance components. Alcoa has deep expertise in metal alloy development having invented most of the aluminum alloys used in aerospace today. In addition, it has a 100-year history in aluminum metal powder production, primarily for rocket fuel, paint and other products.
The facility will form part of Arconic following separation from Alcoa’s traditional commodity business in the second half of 2016. The plant is part of a $60 million investment in advanced 3-D printing materials and processes that builds on the Company’s 3-D printing capabilities in California, Georgia, Michigan, Pennsylvania and Texas. In addition to producing powders, Alcoa is focused on advancing a range of additive techniques, including its recently unveiled Ampliforge process, a hybrid technique that combines additive and traditional manufacturing. Using the Ampliforge process, Alcoa designs and 3-D prints a near complete part, then treats it using a traditional manufacturing process, such as forging. The process enhances the properties of 3-D printed parts, increasing toughness and strength versus parts made solely by additive manufacturing, and significantly reduces material input. Alcoa is piloting the technique in Pittsburgh and Cleveland.