Cooling heads for Wendelstein
7-x fUSIONSREAKTOR

Wendelstein 7-X is an experimental facility of the Max Planck Institute for Plasma Physics in Greifswald of the stellarator type for research into nuclear fusion technology. W7-X is intended to investigate the physical and technical fundamentals and to demonstrate the principal power plant suitability of stellarators as an alternative to the tokamak principle.

The water-cooled 3D heads are used for thermal monitoring of the divertors located in the plasma vessel and protect the mounted mirrors inside. Due to the plasma-exposed position and the complex mounting position, the components must meet the highest requirements for magnetic properties, thermal stress, corrosion resistance and shape and bearing tolerances.

With Rosswag Engineering's holistic process chain, it was possible to carry out all production steps in-house, from 3D-printing to CNC machining and material analysis, to ensure complete documentation of all data and interfaces.

 

Max Planck IPP

 

hpex® High-Performance Heat exchanger

for fuel cell and hydrogen applications

Together with our partners Hülsenbusch Apparatebau and the Institute of Thermodynamics at Leibniz Universität Hannover, new high-performance heat exchangers for applications up to 1000 °C were developed as part of the MultiSchIBZ research project. The heat exchangers are used for thermal management in SOFC fuel cell modules. The volume of the novel heat exchangers is about 25 times smaller than conventional shell-and-tube heat exchangers - with low pressure losses. The robust design allows use for high pressures. Depending on the operating temperatures and requirements, the steels qualified at Rosswag can be 1.4404 (AISI 316L), 1.4828 (AISI 309) or nickel-based materials such as Inconel 625.

In addition to fuel cells, they are also very suitable for hydrogen applications or other industries in which high power densities and low pressure losses in a small installation space are part of the requirement profile.

 

Leibniz University Hülsenbusch

 

Guide vane clusters for gas turbines

In a qualification project lasting several years together with MAN Energy Solutions (formerly MAN Diesel & Turbo), Rosswag Engineering qualified the additive manufacturing of guide vane segments for the MGT6100 gas turbine. The objective was to develop a new value-added product based on 13 individual components of an assembly through functional integration.

Through the holistic and in-house process chain with the necessary manufacturing processes of metal powder qualification, SLM production, heat treatment, surface finish, CNC machining and cross-process quality assurance, the decisive framework conditions for subsequent series production were established. Rosswag was able to support the development activities with its in-depth process and materials know-how.

With this project, MAN Energy Solutions demonstrates in an innovative way how additive manufacturing can also be used sensibly in traditional energy machine construction by integrating functional added value.

 

MAN Video MAN Energy Solutions

 

Functionally optimized lightweight bearings

In cooperation with Franke GmbH, lightweight bearings are produced in which the advantages of metal 3D-printing are combined with innovative wire-race bearing technology.

In wire-race bearings, the rolling process does not take place directly between the rolling element and the surrounding structure, but instead on the races with low friction. Their compact and highly loadable four-point geometries allow maximum design freedom.

Rosswag Engineering qualifies and manufactures the associated lightweight bearing rings in the LPBF process. The topology-optimized structures result in a large weight reduction, while the stiffness of the component still meets the requirements. Rosswag contributes its extensive expertise in design optimization, material selection and holistic production planning.

 

Lightweight bearing Franke GmbH

 

Cooling-optimized series turning tools

Rosswag and ARNO Werkzeuge present the world's first additively manufactured series turning tool in the form of a grooving module.

Two cooling channels in a very small space: The additively manufactured module including ACS2 - ARNO Cooling System - opens up new perspectives for narrow recesses and partings. This results in new possibilities for material savings and increased efficiency. The cooling channels convince with flow-optimized geometries. The lower channel ends in a triangle for optimum cooling up to the edge of the clearance angle. This further increases tool life, shapes shorter chips, and reduces chip sticking and flank wear. So you can be cool to the challenges of the future.

 

Further information Online-shop Patent specification

 

ForgeBrid®

Hybrid combination of forging and metal 3D-printing

The in-house combination of the two manufacturing processes of forging and metal 3D-printing results in new products that can be manufactured efficiently despite high complexity thanks to the innovative process chain.

Rosswag Engineering addresses the existing restrictions of the two manufacturing processes and pursues the goal of optimizing the entire process chain. The innovation consists of manufacturing massive component areas, with a large proportion of material volume, close to the contour using an open-die forging process. Additive manufacturing is then applied to the highly stressable base body in order to add the complex and functionally optimized structures. In this case, channels for air flow control were integrated into the blades.

With the ForgeBrid® process chain, safety-relevant and highly stressed components can also be combined with function-optimized structures from additive manufacturing for the first time. In addition, in-house metal powder production also makes it possible to produce hybrid components from an identical batch of materials.

The ForgeBrid® approach has won several innovation awards for the in-house combination of traditional and additive manufacturing.

Video

Titanium wheel carrier for Formula Student

Functional components for automotive racing often place high demands on the optimal ratio between stiffness and weight. The possibilities of metal 3D-printing enable the efficient production of functionally optimized components even in small quantities. Rosswag Engineering realizes a fast supply of high-quality components made of a variety of different materials through its in-house process chain.

As a sponsor of the student initiative KA-RaceIng e.V., we have been contributing to a successful season for several years. Among other things, the components manifold, intake manifold and wheel carrier are made of aluminum, stainless steel and titanium with our manufacturing processes. In the case of the wheel carrier shown, more than 40% weight was saved while maintaining the same stiffness. The component geometry was created through an iterative optimization process in which the students were able to draw on know-how built up over many years and the company's in-house manufacturing capabilities. The wheel carrier was jointly optimized for manufacture using metal 3D-printing. Furthermore, the subsequent process steps of heat treatment and CNC finishing were also taken into account in the design optimization and carried out by Rosswag.

 

KA-RaceIng Simulations

 

Cooling optimized side milling cutter

From its own needs with over 40 CNC machining centers, Rosswag has been involved in the additive manufacturing of function-optimized cutting tools since 2013. The focus here is on the integration of an optimized cooling lubricant supply for the tool cutting edge.

For cooling-optimized side milling cutters, the first prototypes were developed and successfully validated together with well-known tool manufacturers. Compared to flood cooling lubrication, the tool life of the inserts could be increased by more than 60 %.

The results of the developments are patented by Rosswag and commercial exploitation is planned in several cooperations.

 

Patent specification Side milling cutter

 

Lightweight seating sled for paralympic biathlon

Through extensive sensor technology and subsequent topology optimization, the basic body of the seating sled was designed to meet the individual requirements of athletes. The additive manufacturing of the function-optimized geometry was carried out from high-strength aluminum with a weight saving of over 20%. Additive manufacturing was the only way to achieve an optimal and precisely fitting design for the prevailing boundary conditions during double-stick thrust and tip-over at the shooting range.

The seating sled is to help a junior biathlete to victory at the next Paralympic Winter Games. She will be supported by Team Snowstorm under the leadership of Matthias Scherge, Professor of Microtribology at the Karlsruhe Institute of Technology (KIT).

 

Team Snowstorm Simulations

 

Project Drahtesel Spokeless bike

Rosswag and ANSYS present the "Drahtesel" project, a spoke-less bicycle with connecting elements from metal 3D-printing.

The production of bicycles in small quantities brings many challenges. One of them is the cost-efficient production of individual and highly functional metal components. The metal 3D-printing manufacturing process is precisely suited to these requirements, as it can be used to produce complex component geometries with a high degree of accuracy and very good mechanical properties. In order to be able to analyze and compensate for process-related dimensional deviations due to thermally induced residual stresses even before the production process for the first component, we use the ANSYS Additive simulation environment.

 

Simulations Video ANSYS

 

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