Shifting towards carbon-neutral operations is a priority for all industries, and as additive manufacturing (AM) is approaching industrialization, it is helping businesses find new ways to reduce their environmental impact. There are several areas where AM could have a huge, positive influence once the right solutions are widely adopted. The use of construction steels in AM is one of these areas.
Investing in additive manufacturing can help improve sustainability in multiple ways while also being a way for many businesses to become more profitable and efficient. It can help reduce the number of steps in manufacturing, for example, as shapes that were impossible to make in a single process with traditional methods are now viable through 3D printing. It can also dramatically reduce lead time and help to reduce inventories of spare parts. And there is less wastage due to AM processes as it is possible to use more precise amounts of raw material compared to alternative options.
Steels are the most widely used metal alloys in the industry. However, the adoption of construction steels has been slow as the AM industry has focused on higher-value applications in industries such as aerospace and medical. Expanding the AM market and promoting wider adoption of using construction steels in AM processes will help businesses become more efficient while reducing their carbon footprint.
Meeting Industry Demands
In the past, additive manufacturing was considered too expensive to be able to produce components from traditional construction steel. Construction steel powder offerings practically did not exist in the market and knowledge regarding manufacturing parameters has been missing. These issues have prevented the wider acceptance of AM construction steels. However, Höganäs knows the positive impact that a broader range of viable materials could have on the industry and has designed a portfolio of construction steels specifically engineered to meet industry demands.
“At Höganäs, we believe additive manufacturing is coming into its industrialization phase,” says Jerome Stanley, Director of Global Sales for Customization Technologies at Höganäs. “As we want the benefits of AM to be available to all industries, we have developed a wide-ranging portfolio of products, and within that, we can provide optimal solutions for many different industrial applications.”
Low-alloyed construction steels can be used in the production of many different types of components that can be found anywhere from the cars we drive to the heavy machinery and tools used on the industrial production shop floor.
It’s also common in all industries that broken spare parts have to be replaced in a short time to be able to quickly resume operations and avoid extensive losses associated with production downtime. AM of construction steels can be specifically useful in this type of scenario. Being able to produce spare parts on demand means it is possible to reconsider the need for spare parts inventory, which leads to both economical gain and improved sustainability.
"As we want the benefits of AM to be available to all industries, we have developed a wide-ranging portfolio of products, and within that, we can provide optimal solutions for many different industry applications"
“We have already seen how much of a difference AM can make in terms of both resource and process efficiency,” says Denis Oshchepkov, Product Manager at Höganäs, “and with our range of construction steels, we are making AM more viable to all industries that still rely on other methods for their production. In addition to the efficiency gains, these products can help more industries move towards net zero carbon emissions.”
Engineered to Last
Common priorities for low-alloyed construction steels, regardless of application, are mechanical properties and processability. The Höganäs portfolio of construction steel powders includes products designed for different types of heat treatments, as well as applications where only simple stress relief after component production is required. Höganäs also provides printing parameters and heat treatment recommendations to ensure the end results will meet, or even exceed expectations.
“We are one of the pioneers in the introduction of construction steels in AM industry,” explains Oshchepkov. “Our products open up new opportunities for the production of spare parts and components in sectors such as automotive, heavy construction equipment, mining, and tooling. Even small individual reductions in total emissions from manufacturing can make a big difference.”
Using construction steels for AM benefits sustainability in several ways. Not only does it help to control the use of valuable resources and improve process efficiency, but the resulting parts can also be more durable. This means the parts last for longer periods before replacements are required, which reduces waste and, in turn, carbon emissions. The parts that do eventually reach end-of-life are also easier to recycle and reuse than their aluminium-alloy-based counterparts, further improving overall sustainability and reducing environmental impact.
Embracing the Future Faster
In addition to the sustainability benefits, this new class of AM materials can also help businesses develop new solutions more quickly, and in turn, experience the benefits sooner than they would with alternative methods. This is because the process is much shorter – the designer creates the 3D file, chooses the required grade of construction steel, and then it can be printed and tested.
In broader terms, this will mean all industries can evolve faster than before. It also means designers and engineers are more empowered to make bold decisions, as each prototype isn’t as big of an investment in terms of time or money.
“We’re confident that our construction steel powders will benefit industry, and the industrialization of AM itself,” says Stanley. “We’ve designed them to offer heat treatment processes similar to wrought construction steels while offering all benefits of additive manufacturing technology. This means more businesses can make the switch to AM without making any sacrifices but, instead, experience the many associated benefits.”
Additive manufacturing is already making a positive impact in many sectors. Now, without the limitations seen in the past, it can also bring these benefits to industries where low-alloyed construction steels are essential. With Höganäs leading the initiative, the powder products will only go from strength to strength.
