Novel Process to Reduce Rhodium Expense

Rhodium, the rarest occurring metal.

Renishaw PLC, Gloucestershire, UK, has delivered a crucial saving for a metal additive manufacturing (AM) process that involves rhodium and platinum, two metals that are generally too expensive to use in industrial applications. However, when alloyed, weight loss at high temperatures occurs slower than pure platinum, providing industrial value.

Cookson Industrial, a subsidiary of HM Precious Metals, is a precious metal AM producer in the U.K. Its goal to use AM for platinum rhodium parts for catalysts and aerospace engine nozzles had been unsuccessful due to too much waste. Previously, powder waste levels were as low as 1.5%. However, Cookson Industrial's standards are less than 0.5%.

But, working closely as a team, the process was developed for the specific demands of platinum rhodium production. Customizations included modifying internal system components to prevent powder accumulation, such as removing "overflow bellows and optimizing the rear overflow vent". Chamber redesigns and the creation of specialized casings and covers, resulting in an additional 95% reduction in powder waste.

The new process has exceptional material utilization and high-temperature corrosion-resistant platinum rhodium parts on a commercial scale for industries.