A close collaboration between ArcelorMittal R&D organization and Materials & Advanced Manufacturing Research Group MOD3RN at Nebrija University in Spain has resulted in the manufacture of a steel chassis that could revolutionize the world of motorcycles. In general, the most widespread material in the world of motorcycles is aluminum, with some exceptions in steel. Managing to develop a steel chassis capable of equaling or improving the lightness of aluminum and that provides a driving sensation and performance similar to that of this material is one of the milestones achieved by this alliance between ArcelorMittal and Nebrija. In order to make a steel piece lighter than an aluminum or titanium one thanks to 3D printing, Nebrija University researchers designed very innovative geometric shapes that allowed the pieces to be hollow.The possibility of generating hollow parts was the main unknown in metal 3D printing. Wall thicknesses of between 0.8 and 1 millimeter in the chassis involved addressing several issues within 3D printing including stability of the piece during the printing process as a result of the very low thicknesses, control of porosities and mechanical properties in these thicknesses and orientation of the geometric shape to avoid internal supports. These unknowns were resolved throughout the joint research project thanks to certain properties that steel provides in the printing process and that made it possible for the realization of hollow pieces to become a reality.Once the stability of the steel with these thicknesses was confirmed and the mechanical properties guaranteed, these boundary conditions were integrated into the intelligent design algorithms so that they were automatically capable of generating a range of innovative geometric shapes that were stable over time, to be printed and whose design respected at all times certain orientations that would avoid the generation of internal supports.The design of the chassis -whole, hollow and with thicknesses of only 0.8 to 1 millimeter- is the result of geometric innovation and the expert knowledge of the designers involved in the process. It is probably one of the few 3D printed hollow parts that exist so large, with such a demanding application and with such a low weight. This steel chassis weighs approximately 3.8 kilos. Aluminum chassis from top-tier brands do not go below 5 kilos, while other steel chassis can shoot up to 6-7 kg. It seems that the difference is small, but losing grams in this type of pieces is very, very difficult, so talking about several kilos is a huge advanceIt should be noted that a new steel alloy has not been developed within the framework of this project. Excellent results are achieved with a widely available standard product in the form of powdered steel for additive manufacturing processes. Therefore, beyond the results of the chassis, the generation of steel parts that can compete for lightness with those of aluminum or titanium can enable a change in this industry, since, combining additive manufacturing with a choice of a grade of suitable steel can be even more competitive in terms of cost. This project opens a door for certain components to be manufactured in steel, thus allowing the return of this material to many applications in this business sector within the world of motorcycling competition.At its technological innovation center in Asturias, ArcelorMittal carries out research oriented towards the application of cutting-edge digital technologies, such as 3D printing or artificial intelligence, in the steel industry, from production processes to the applications of products. Nebrija University integrates artificial intelligence techniques and generative models -intelligent design or generative design- to develop products that can contribute to generating new success stories within a research and innovation environment, applied in this case to the competition industry in automotive. The automotive area is one of the mainstays of Nebrija University, which integrates the Master's Degree in Racing Vehicle Engineering, the Degree in Automotive Engineering, with the collaboration of Yamaha MS Racing-, the Nebrija Automobile Club and special collaborations such as that of the Astara Team in the 2022 Dakar Rally.
A close collaboration between ArcelorMittal R&D organization and Materials & Advanced Manufacturing Research Group MOD3RN at Nebrija University in Spain has resulted in the manufacture of a steel chassis that could revolutionize the world of motorcycles. In general, the most widespread material in the world of motorcycles is aluminum, with some exceptions in steel. Managing to develop a steel chassis capable of equaling or improving the lightness of aluminum and that provides a driving sensation and performance similar to that of this material is one of the milestones achieved by this alliance between ArcelorMittal and Nebrija. In order to make a steel piece lighter than an aluminum or titanium one thanks to 3D printing, Nebrija University researchers designed very innovative geometric shapes that allowed the pieces to be hollow.The possibility of generating hollow parts was the main unknown in metal 3D printing. Wall thicknesses of between 0.8 and 1 millimeter in the chassis involved addressing several issues within 3D printing including stability of the piece during the printing process as a result of the very low thicknesses, control of porosities and mechanical properties in these thicknesses and orientation of the geometric shape to avoid internal supports. These unknowns were resolved throughout the joint research project thanks to certain properties that steel provides in the printing process and that made it possible for the realization of hollow pieces to become a reality.Once the stability of the steel with these thicknesses was confirmed and the mechanical properties guaranteed, these boundary conditions were integrated into the intelligent design algorithms so that they were automatically capable of generating a range of innovative geometric shapes that were stable over time, to be printed and whose design respected at all times certain orientations that would avoid the generation of internal supports.The design of the chassis -whole, hollow and with thicknesses of only 0.8 to 1 millimeter- is the result of geometric innovation and the expert knowledge of the designers involved in the process. It is probably one of the few 3D printed hollow parts that exist so large, with such a demanding application and with such a low weight. This steel chassis weighs approximately 3.8 kilos. Aluminum chassis from top-tier brands do not go below 5 kilos, while other steel chassis can shoot up to 6-7 kg. It seems that the difference is small, but losing grams in this type of pieces is very, very difficult, so talking about several kilos is a huge advanceIt should be noted that a new steel alloy has not been developed within the framework of this project. Excellent results are achieved with a widely available standard product in the form of powdered steel for additive manufacturing processes. Therefore, beyond the results of the chassis, the generation of steel parts that can compete for lightness with those of aluminum or titanium can enable a change in this industry, since, combining additive manufacturing with a choice of a grade of suitable steel can be even more competitive in terms of cost. This project opens a door for certain components to be manufactured in steel, thus allowing the return of this material to many applications in this business sector within the world of motorcycling competition.At its technological innovation center in Asturias, ArcelorMittal carries out research oriented towards the application of cutting-edge digital technologies, such as 3D printing or artificial intelligence, in the steel industry, from production processes to the applications of products. Nebrija University integrates artificial intelligence techniques and generative models -intelligent design or generative design- to develop products that can contribute to generating new success stories within a research and innovation environment, applied in this case to the competition industry in automotive. The automotive area is one of the mainstays of Nebrija University, which integrates the Master's Degree in Racing Vehicle Engineering, the Degree in Automotive Engineering, with the collaboration of Yamaha MS Racing-, the Nebrija Automobile Club and special collaborations such as that of the Astara Team in the 2022 Dakar Rally.
