Can you spin a plane out of wire?
Aerospace components are increasingly complex both in terms of geometries and materials used. Innovative manufacturing technologies are needed to enhance performance and sustainability while reducing costs. Laser wire deposition is an emerging additive manufacturing approach that addresses both these needs, but better control over the robotic process is needed. The EU-funded ASSALA project delivered process monitoring and control tools that will lead to higher-quality parts produced from melted wire faster, and at a lower cost than currently possible. The project has now been featured in the new CORDIS series of explanatory videos titled Make the Connection with EU Science. “Our team increased the robotic accuracy of most kinematic parameters by 13-81 %,” says Jon Lambarri, researcher at the Advanced Manufacturing Processes Unit at Tekniker and project coordinator. “Our methodology enables real-time evaluation of target parameters and process inaccuracies, and correction of detected inaccuracies thanks to optimisation algorithms.” The manufacturing lead time for titanium die forging is approximately 8 to 10 months, and each part requires its own die forging, with its own expensive dies that must first be qualified by testing mechanical and fatigue properties. In contrast, titanium wire can be obtained in a few weeks and used for all titanium parts. ASSALA’s work will enhance the adoption of promising laser wire deposition technology to produce large, geometrically complex parts, boosting the competitiveness of the European aerospace sector. ‘Make the connection with EU-science’ is a series of explanatory videos focusing on the scientific content and exploitation aspects of EU research projects.
Keywords
ASSALA, LWD, aerospace, AM, process control, titanium alloy, robotic, laser wire deposition, additive manufacturing, laser metal deposition