revolutionary tailored ARChitected Heterostructures obtained by solId state DEPosition

Project Information

ArcHIDep

Grant agreement ID: 101044228

DOI

10.3030/101044228

EC signature date 31 October 2022

Start date 1 January 2023

End date 31 December 2028

Funded under

• European Research Council (ERC)

Total cost

€ 1 998 000,00

EU contribution

€ 1 998 000,00

Coordinated by

POLITECNICO DI MILANO
Italy

Periodic Reporting for period 1 - ArcHIDep (revolutionary tailored ARChitected Heterostructures obtained by solId state DEPosition)

Reporting period: 2023-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

Despite the great promise and expectations, current additive manufacturing technologies still struggle to offer the flexibility needed for desired control over the chemical composition, inner arrangement, and outer shape of multi-material structures. To address this gap, the ArcHIDep project leverages the unique opportunities provided by a versatile solid-state powder deposition technique known as cold spray deposition. This technique offers a high deposition rate and the ability to mix materials with different chemical, microstructural, or mechanical properties.
ArcHIDep aims to establish a design framework that combines analytical, experimental, and numerical approaches to enable the implementation of customized multiscale heterogeneity at both compositional, microstructural, and geometrical levels. This framework will exploit the synergy between heterogeneity indexes designed at multiple length scales, tailoring the continuum-level behavior of the integrated structure. Enabling customized heterogeneity can offer an exceptional solution for complex structures in demanding fields where multiple competing or site-specific requirements often exist for a single component.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The activities within the ArcHIDep project are organized into several key themes to explore the role of various categories of heterogeneity within additive manufacturing, including geometrical, microstructural, and chemical. We investigate how these different forms of heterogeneity can be leveraged to modulate the mechanical response of metallic structures. We employ theoretical, numerical, and experimental approaches to excel in the design, development, characterization, and deployment of these architected heterogeneous structures.
Additionally, we are developing innovative shape control strategies in solid-state additive manufacturing and repair, which will facilitate the establishment of this solid-state deposition technique for additive manufacturing. The findings hold significant potential for transformative applications across aerospace, automotive, biomedical, and numerous other fields.

More information about the work performed within this project and its main achievements can be found at: https://www.archeslab.polimi.it/research/

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The results of the activities dedicated to shape prediction in cold spray go beyond the state of the art. In this regard, the developed data-driven framework paves the way for the automation of CS additive manufacturing with respect to shape control. This Code is being expanded and evaluated in an ERC_POC project to the specific case of repair and restoration, where the market analysis and commercialization aspects will be explored.
A detailed framework is also developed for the inverse design of lattice structures with geometrical heterogeneity, regardless of the AM technique.

ArcHIDep activities on implementing and characterizing heterogeneities at different length scales