Development of a technology for the manufacturing of parts/components of an internal combustion engine involving additive manufacturing methods

Introduction: the article considers a strategic objective consisting in reduction of the Russian companies’ dependence on highly sought-after imported power engineering equipment, including internal combustion engines used as part of auxiliary power units. In the article, the co-authors propose to integrate additive manufacturing methods into technologies used to produce internal combustion engines, their parts and components, which are temporarily or permanently impossible to import. The co-authors have proven the feasibility of advanced additive technologies in respect of casting molds and castings designated for internal combustion engines. An alloy of cast iron featuring an advanced chemical composition was developed. It enables the use of complex shape castings free from any non-metallic inclusions to produce engine parts and components; these castings demonstrate higher values of strength and wear resistance, they are a must for an internal combustion engine operating in severe conditions. The co-authors demonstrate the casting mold production process using ExOne’s S-MAX 3D printer.Methods: the study is based on the analysis of strengths, weaknesses and peculiarities of established casting methods, with account for faster production cycles and a higher quality of final products.Results and discussion: in the article, the co-authors analyze the proposed technology used to manufacture castings for “a block of cylindersˮ and “a head of the block of cylindersˮ.Conclusion: the newly developed technology for production of parts/assemblies of an internal combustion engine, including an advanced alloy having a new chemical composition, enables manufacturers to make high quality parts/ assemblies for an internal combustion engine in the most economical and productive way.