Objective AMATHO (A.dditive MA.nufacturing T.iltrotor HO.using) is aimed to design, assess and manufacture a novel tiltrotor drive system housing exploiting the features of additive manufacturing techniques. Preliminarily, functional, structural and technological peculiarities of rotorcraft main gearbox housings are analysed and relevant requirements are issued. In the meantime, viable AM processes are reviewed, on the basis of specific suitability, technological potential and degree of maturity. In particular, powder feed direct energy deposition techniques (Direct Laser Deposition - DLD) and powder bed fusion techniques (Selective Laser Melting - SLM and Electron Beam Meelting - EBM) are considered. The powder precursors are investigated as well, in terms of chemical nature (magnesium, aluminium, titanium alloy, stainless steel), particles granulometry and morphology. Static, fatigue, fracture mechanics, damage tolerance, corrosion endurance, chemical compatibility, machinability, weldability and heat-treatability testing are worked out and final trade-off process accomplished for choosing optimal materials and processes. Characterisation methodologies and NDI techniques are assessed as well. In addition to test activity on dedicated specimens, smaller, but fully representative, full-scale gearbox housing components (to be considered as proof of concept) are manufactured through the traded-off technologies and tested to check the compliance with general functional aspects of r/c drive system housing. In parallel, design rules and methodologies for detail design, optimisation and structural substantiation of AM components are defined and supporting numerical tools are set-up. Full-scale housing is manufactured and structural and functional tests are performed to support flight clearance on the NextGenCTR Demonstrator and procedures (engineering cost and industrial capability assessment) for the start-up of high-volume production are defined Fields of science engineering and technologymechanical engineeringmanufacturing engineeringsubtractive manufacturingnatural scienceschemical sciencesinorganic chemistrypost-transition metalsengineering and technologymechanical engineeringvehicle engineeringaerospace engineeringaircraftrotorcraftengineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturingnatural sciencesphysical sciencesopticslaser physics Keywords Additive Manufacturing Tiltrotor Monolithic Housing Helicopter drive system Mechatronic Real_time control CAE CAM DED DLD EBM LBW SLM Metal Powder Testing 3D Vision Welding Laser Programme(s) H2020-EU.3.4. - SOCIETAL CHALLENGES - Smart, Green And Integrated Transport Main Programme H2020-EU.3.4.5.3. - IADP Fast Rotorcraft Topic(s) JTI-CS2-2015-CFP02-FRC-01-03 - Development and validation of an optimised gearbox housing structural design and manufacturing process, based on additive layer manufacturing concept leading to a flight cleared demonstrator. Call for proposal H2020-CS2-CFP02-2015-01 See other projects for this call Funding Scheme IA - Innovation action Coordinator POLITECNICO DI MILANO Net EU contribution € 1 250 000,00 Address PIAZZA LEONARDO DA VINCI 32 20133 Milano Italy See on map Region Nord-Ovest Lombardia Milano Activity type Higher or Secondary Education Establishments Links Contact the organisation Opens in new window Website Opens in new window Participation in EU R&I programmes Opens in new window HORIZON collaboration network Opens in new window Total cost € 1 250 000,00 Participants (2) Sort alphabetically Sort by Net EU contribution Expand all Collapse all SCUOLA UNIVERSITARIA PROFESSIONALE DELLA SVIZZERA ITALIANA Switzerland Net EU contribution € 0,00 Address STABILE LE GERRE 6928 Manno See on map Region Schweiz/Suisse/Svizzera Ticino Ticino Activity type Higher or Secondary Education Establishments Links Contact the organisation Opens in new window Website Opens in new window Participation in EU R&I programmes Opens in new window HORIZON collaboration network Opens in new window Total cost € 1 356 875,00 PRIMA INDUSTRIE SPA Italy Net EU contribution € 499 999,50 Address VIA TORINO-PIANEZZA 36 10093 COLLEGNO See on map Region Nord-Ovest Piemonte Torino Activity type Private for-profit entities (excluding Higher or Secondary Education Establishments) Links Contact the organisation Opens in new window Website Opens in new window Participation in EU R&I programmes Opens in new window HORIZON collaboration network Opens in new window Total cost € 714 285,00
