A Technical University of Denmark (DTU)-led team of engineers has turned towards 3D printing to create cargo ship parts – like large marine engines – that complement greener fuel consumption.
The main focus of this collaborative effort between DTU and MAN Energy Solutions is the injection nozzle, which injects fuel into the engine, where it is mixed with oxygen to ensure optimal combustion.
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DTH postdoc Thomas Dahmen is the brain behind this new endeavor; he has been carrying out a Quality Deployment Function (QFD) analysis for 3D printing.
3D-QFD is an analysis model used to provide an overview of the value 3D printing can add to a product as a whole.
“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 Dahmen.
According to Dahmen, the improvement of the injection nozzle was based on the fact that a better fuel flow could be achieved with a slightly different – and more curved – design. In this way, the new nozzle design contributes to improved engine combustion.
Initial trials also suggest that the nozzle could potentially help reduce NOx emissions from the engine, but further studies will be required to demonstrate such an effect.
These promising results prompted Dahmen to try the new 3D printed injection nozzle on MAN Energy Solutions’ full-scale test engine at Research Center Copenhagen.
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“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,” says MAN Energy Solutions mechanical engineer Peter Hagen.
“This made a collaboration with DTU on exploring the potential an obvious choice. The test went well, and we look forward to doing a long-run test next,” says Hagen.
“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.”
In addition to looking at the nozzle design, Dahmen also compared the pros and cons of two different 3D printing techniques – Laser Powder Bed Fusion and Binder Jetting – with the latter becoming the more obvious choice.
According to Dahmen, Binder Jetting encourages intricate flow-related nozzle features and special high-temperature materials that would be impossible to realize with other manufacturing processes.
Image and content: Eric G. Lund/Technical University of Denmark (DTU)
