Periodic Reporting for period 3 - MULTI-FUN (Enabling MULTI-FUNctional performance through multi-material additive manufacturing)
Période du rapport: 2022-09-01 au 2023-12-31
The focus of MULTI-FUN was set on pushing the limits for multi-material parts created by means of Wire Arc Additive Manufacturing (WAAM) and other Direct Energy Deposition (DED) methods for metal & ceramic feedstock. New material combinations are providing significant performance and efficiency boost to additively manufactured metal products through fully integrated multi-functionalities which include embedded electrical conductors, fibre-optics based distributed sensing features & innovative heat management concepts.
MULTI-FUN created 7 1:1 scaled demonstrators (DEMO1-7) for 3 different use cases (Structural parts, Moulds and Test equipment), representing 10 different material combinations sized in the range from 5cm to nearly 1m., directly addressing the sectors automotive, aviation, space and production industries.
MULTI-FUN created 7 1:1 scaled demonstrators (DEMO1-7) for 3 different use cases (Structural parts, Moulds and Test equipment), representing 10 different material combinations sized in the range from 5cm to nearly 1m., directly addressing the sectors automotive, aviation, space and production industries.
WP1 Life cycle analysis and impact assessment (LCA) covered the environmental impacts acc. to ISO 14040 and 14044 standards. The LCA method RECIPE was applied for 13 impact categories in deliverable D1.3. Health & Safety (HSE) activities treated the nanoparticles emission monitoring at several partners sites.
WP2 Advanced AM Materials for multifunctional performance (MATERIALS) treated several novel AM materials, incl. Cu-coated Mo & W particles and AlTiC, AlTiB2, and FeCrAl powders, novel Al alloys and optical fibre with Ni and/or Cu coatings. Multi-material designs were investigated for steel, INVAR , Cu and Al alloys as well as ceramics.
WP3 Advanced AM-Equipment for in-situ -Multi-Functionalities by Multi-Materials (EQUIPMENT) focused systems for wire and powder, applying electric arc, laser or plasma energy. Deposition of powders with conductive & insulating properties was improved. Software enabling the multi-material and multi-functionality of part manufacturing was adopted for a faster and more reliable processing.
WP4 Evaluation of Multi-Materials and Multi-Functionalities (EVALUATION) covered the characterization of bulk microstructures and interfaces, regarding mechanical and thermal properties. Visual, ultrasonic and x-ray radiography testing incl. Synchrotron micro-tomography analysis provided detailed insight into samples and real size demonstrators regarding porosity, lack of fusion, multi-material interfaces and the integrity of embedded optical fibres and electrical conductors.
WP5 Use Case Demonstrations (USE CASES) successfully achieved the design and manufacturing of all 7 demonstrators:
DEMO1 – Actuator Housing (for space application, thumb-sized, out of standard stainless steel plus integrated standard copper, doubling the heat transfer rates)
DEMO2 – Bulkhead Panel (aviation related hybrid part out of standard aerospace & novel aluminium grade alloy in combination with coated optical fibres adding an embedded structural health monitoring (SHM) capability. The metal coating of OFs and equipment for OF integration by WAAM were subject matters of 2 patent applications. An eco-efficiency improvement of >60% was achieved.
DEMO3 – See through A-pillar (WAAM of standard steel grade in combination with standard CANbus cables integrated by APPD zinc coating) features a revolutionary design solving the vehicle safety issue of blind spots.
DEMO4 – Motorbike Handlebar (Novel aluminium alloy combined with Al2O3 insulation layers and copper conductors substituting electrical cables (for lights, indicators or starter) in a WAAM aluminium structure besides integrated hydraulic channels.)
DEMO5 – Die insert (Standard tool steel combined with sintered, nanotechnology-based DiaCool sintered feedstock) for aluminium die casting.
DEMO6 – Mould for CFRP Parts (Invar plus copper) designed for electr. heated, out-of-autoclave manufacturing of carbon-fibre reinforced polymers) indicating a potential to raise an eco-efficiency improvement >25%.
DEMO7 – Hydrogen Gas Temperature Control unit (Novel aluminium alloy coated with ceramic insulation layers , integration of OFs in spiral manner) for increased dynamics in H2 preconditioning.
Lessons learnt across all demonstrators were published as a report (deliverable).
WP6 Dissemination, Exploitation & Communication (DEC) focused on dissemination via papers, presentations etc., conducted 4 public events (2 SpeedTech Forums , 1 MULTI-FUN Talks, 1 training session) and participated in working group on standardisation.
WP2 Advanced AM Materials for multifunctional performance (MATERIALS) treated several novel AM materials, incl. Cu-coated Mo & W particles and AlTiC, AlTiB2, and FeCrAl powders, novel Al alloys and optical fibre with Ni and/or Cu coatings. Multi-material designs were investigated for steel, INVAR , Cu and Al alloys as well as ceramics.
WP3 Advanced AM-Equipment for in-situ -Multi-Functionalities by Multi-Materials (EQUIPMENT) focused systems for wire and powder, applying electric arc, laser or plasma energy. Deposition of powders with conductive & insulating properties was improved. Software enabling the multi-material and multi-functionality of part manufacturing was adopted for a faster and more reliable processing.
WP4 Evaluation of Multi-Materials and Multi-Functionalities (EVALUATION) covered the characterization of bulk microstructures and interfaces, regarding mechanical and thermal properties. Visual, ultrasonic and x-ray radiography testing incl. Synchrotron micro-tomography analysis provided detailed insight into samples and real size demonstrators regarding porosity, lack of fusion, multi-material interfaces and the integrity of embedded optical fibres and electrical conductors.
WP5 Use Case Demonstrations (USE CASES) successfully achieved the design and manufacturing of all 7 demonstrators:
DEMO1 – Actuator Housing (for space application, thumb-sized, out of standard stainless steel plus integrated standard copper, doubling the heat transfer rates)
DEMO2 – Bulkhead Panel (aviation related hybrid part out of standard aerospace & novel aluminium grade alloy in combination with coated optical fibres adding an embedded structural health monitoring (SHM) capability. The metal coating of OFs and equipment for OF integration by WAAM were subject matters of 2 patent applications. An eco-efficiency improvement of >60% was achieved.
DEMO3 – See through A-pillar (WAAM of standard steel grade in combination with standard CANbus cables integrated by APPD zinc coating) features a revolutionary design solving the vehicle safety issue of blind spots.
DEMO4 – Motorbike Handlebar (Novel aluminium alloy combined with Al2O3 insulation layers and copper conductors substituting electrical cables (for lights, indicators or starter) in a WAAM aluminium structure besides integrated hydraulic channels.)
DEMO5 – Die insert (Standard tool steel combined with sintered, nanotechnology-based DiaCool sintered feedstock) for aluminium die casting.
DEMO6 – Mould for CFRP Parts (Invar plus copper) designed for electr. heated, out-of-autoclave manufacturing of carbon-fibre reinforced polymers) indicating a potential to raise an eco-efficiency improvement >25%.
DEMO7 – Hydrogen Gas Temperature Control unit (Novel aluminium alloy coated with ceramic insulation layers , integration of OFs in spiral manner) for increased dynamics in H2 preconditioning.
Lessons learnt across all demonstrators were published as a report (deliverable).
WP6 Dissemination, Exploitation & Communication (DEC) focused on dissemination via papers, presentations etc., conducted 4 public events (2 SpeedTech Forums , 1 MULTI-FUN Talks, 1 training session) and participated in working group on standardisation.
MULTI-FUN will overcome PBF-LB process restrictions by:
Provide a significant performance & efficiency gain in MAM products by fully integrated multi-functionalities based on novel active materials
Enable multi-material design in geometrically complex 3D metal parts without size limitation by innovative, cost-effective AM technologies
Results
1 ADVANCED METALLIC MATERIALS
2 NOVEL AM EQUIPMENT
3 MULTI-MATERIAL DESIGN-KNOWLEDGE
4 STANDARDISATION KNOWLEDGE
Impact
Improvement of the efficiency, quality and reliability of the product exploiting nanotechnology for optimising material parameters, to result in:
- Heat sink material with highest conductivity
- Enhanced local heat transfer efficiency
- Improvement of thermal regulation dynamics, production rates & properties of parts produced
- Increased mould lifetime
- Multi-sectorial approach with high level of transferability to other markets
- Enabling radical new design in load carrying vehicle structures, generating frontrunner position due to gains in safety, reliability and comfort
- Digital integration of multi-functional “wired” parts into condition-based monitoring and digital twin process control leading to reduced downtimes, less scrap & lower energy consumption
- Paving the way for SHM for metal parts into aviation industry
Better use of raw materials and resources with reduced environmental impact and lower cost enabling multi-material parts by exploiting WAAM in cooperation with other cost-effective processes to realize multi-functionalities by added active materials resulting in:
- Significantly reducing production waste
- Integrated functionalities leading to enhanced lifetime
- Highly integrative design leading to reductions in no. of single parts, leading to the reduction in causes of failures and maintenance needs
- Environmental impact supervised by LCA concerning cradle-to-grave energy and raw material consumption
- Reduction of production waste
- Implementation of multi-material forming tools in conventional forming processes for energy reduction & enhanced productivity
- Transfer of multi-material opportunities to other forming processes (hot stamping, composite curing, sintering)
- Opening up radical design concepts for moulds and parts in context of predictive maintenance
- Further improvement in durability and lifespan of machinery by integrated condition sensors
New opportunities & business for SMEs across EU
- Offers along the entire value chain will be developed and distributed by beneficiaries
- Inclusion of insights into curricula of 5 EU Unis
- Set up and delivery of training for SMEs on AM
- Positioning of SMEs as frontrunner for AM-materials, equipment, quality, as international quality leader
- Setting up training activities for SMEs to build and enhance AM capacities throughout EU on the long term
Provide a significant performance & efficiency gain in MAM products by fully integrated multi-functionalities based on novel active materials
Enable multi-material design in geometrically complex 3D metal parts without size limitation by innovative, cost-effective AM technologies
Results
1 ADVANCED METALLIC MATERIALS
2 NOVEL AM EQUIPMENT
3 MULTI-MATERIAL DESIGN-KNOWLEDGE
4 STANDARDISATION KNOWLEDGE
Impact
Improvement of the efficiency, quality and reliability of the product exploiting nanotechnology for optimising material parameters, to result in:
- Heat sink material with highest conductivity
- Enhanced local heat transfer efficiency
- Improvement of thermal regulation dynamics, production rates & properties of parts produced
- Increased mould lifetime
- Multi-sectorial approach with high level of transferability to other markets
- Enabling radical new design in load carrying vehicle structures, generating frontrunner position due to gains in safety, reliability and comfort
- Digital integration of multi-functional “wired” parts into condition-based monitoring and digital twin process control leading to reduced downtimes, less scrap & lower energy consumption
- Paving the way for SHM for metal parts into aviation industry
Better use of raw materials and resources with reduced environmental impact and lower cost enabling multi-material parts by exploiting WAAM in cooperation with other cost-effective processes to realize multi-functionalities by added active materials resulting in:
- Significantly reducing production waste
- Integrated functionalities leading to enhanced lifetime
- Highly integrative design leading to reductions in no. of single parts, leading to the reduction in causes of failures and maintenance needs
- Environmental impact supervised by LCA concerning cradle-to-grave energy and raw material consumption
- Reduction of production waste
- Implementation of multi-material forming tools in conventional forming processes for energy reduction & enhanced productivity
- Transfer of multi-material opportunities to other forming processes (hot stamping, composite curing, sintering)
- Opening up radical design concepts for moulds and parts in context of predictive maintenance
- Further improvement in durability and lifespan of machinery by integrated condition sensors
New opportunities & business for SMEs across EU
- Offers along the entire value chain will be developed and distributed by beneficiaries
- Inclusion of insights into curricula of 5 EU Unis
- Set up and delivery of training for SMEs on AM
- Positioning of SMEs as frontrunner for AM-materials, equipment, quality, as international quality leader
- Setting up training activities for SMEs to build and enhance AM capacities throughout EU on the long term