Diesel Thinkstock

3D Printing Repairs Diesel Engines

3D Printing has the potential to give heavy-duty engines a new lease on life.

Diesel engine maker Cummins Inc. is working with Oak Ridge National Laboratory to developing a material to repair heavy-duty vehicle engines damaged by a million miles of extreme conditions under the hood. Rather than replacing an engine’s cylinder head, the research team “scooped out” the worn section of the cylinder head and used 3D printing to deposit a high-performance alloy patch better than the original casting.

Brittany Cramer/Oak Ridge National Laboratory, U.S. Dept. of Energy

A 3D printing process developed at Oak Ridge National Laboratory repairs and strengthens a Cummins engine without the need to recast parts, which reduces costs and saves energy.

The goal of the process, developed at DOE’s Manufacturing Demonstration Facility at ORNL, is to save energy while extending the life of engines and making them stronger. “We’re decreasing the engine’s thermal conductivity, which holds heat in longer, and turning it into increased efficiency,” says Nikhil Doiphode, Cummins’ parts R&D engineer. “While these are not brand-new engines, we’re striving to make them better than new.”

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