Additive manufacturing as a resource saving alternative in the manufacturing process of marine gearbox housings

Large-volume components, such as gearbox housings for marine gearboxes, are manufactured e.g. as cast components. This is a timeconsuming and complex process, which also places restrictions on the design of the component. Due to the need for a cast-compatible design, it is necessary to oversize the components, which results in a redundant amount of energy and resources from a load perspective. An additively manufactured component, on the other hand, can be produced in a weight- and load-optimized manner. Additive manufacturing therefore offers the opportunity to manufacture in an energy- and resourceefficient manner and to realize designs that cannot be implemented using conventional manufacturing methods. Together with the project partners, REINTJES has developed a demonstrator system in a research project funded by the German Federal Ministry of Economics and Climate Protection (BMWK). This system can be used to manufacture marine gearbox housings in an installation space of 4.5m x 3m x 1.5m. Laserassisted arc deposition welding is used for this purpose. The completed project demonstrated that this process has the potential to save 41% energy and 36% material in the production of marine gearbox housings compared to conventional manufacturing processes. Thanks to the manufacturing process presented, the housings can be designed to withstand loads using bionic structures, among other things, which leads to the corresponding material savings. In addition to extensive design possibilities, it also offers the potential for greater flexibility in production. In the following research project, the need for further research and development, the control of residual stresses and component distortion, will be addressed.

Presentation language: GER

(English translation will be provided on site)