Fasteners—usually the less glamorous part of a mechanical design—have been grabbing headlines lately. First it was a lack of fasteners that created (or was at least blamed for) the first delay announcement for the Boeing Dreamliner. Now two metallurgists have put out a book that really dredges up the past. In “What Really Sank the Titanic” , coauthors Jennifer Hooper McCarty and Tim Foecke say that substandard rivets were responsible for the rapid descent of the supposedly unsinkable vessel. Metallurgical testing of 48 rivets recovered from the Titanic showed that slag concentrations were at 9 percent, six or seven percent higher than they should have been. Slag is a brittle byproduct of the iron making process. Design engineers put the weaker rivets in areas expected to see less stress, such as the bow. Unfortunately, that is right where the Titanic scraped an iceberg. McCarty and Foecke postulate that fewer compartments would have burst if better rivets had been used. It’s possible, they say, that the Titanic could even have limped into Halifax. They also suggest that the bad rivets may have resulted from a rush to get the boat built at a time when rivets were in tight supply.
Siemens and Fraunhofer Institute for Laser Technology have achieved a faster production process based on selective laser melting for speeding up the prototyping of big, complex metal parts in gas turbine engines.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
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