Combining DISsimilar materials into functional large-scale and light-weight COmponents and structures

Project Information

DISCO2030

Grant agreement ID: 101091860

DOI

10.3030/101091860

EC signature date 29 November 2022

Start date 1 December 2022

End date 30 November 2026

Funded under

• Digital, Industry and Space

Total cost

€ 6 555 819,75

EU contribution

€ 6 555 819,75

Coordinated by

TECHNISCHE UNIVERSITAET MUENCHEN
Germany

Periodic Reporting for period 1 - DISCO2030 (Combining DISsimilar materials into functional large-scale and light-weight COmponents and structures)

Reporting period: 2022-12-01 to 2024-05-31

Summary of the context and overall objectives of the project

The DISCO2030 project is developing two hybrid AM methods to join dissimilar metal-metal and metal-polymer materials. The main motivation for joining multiple materials is to achieve multi-functionality, such as in aerospace engines. However, state-of-the-art joining techniques have limitations, such as requiring the components to be machined separately and creating "dead spaces" at the joint. Additive manufacturing (AM) offers a new approach to joining multiple materials, with the potential to create graded materials with locally optimized properties. AM is still in its infancy for dissimilar material joining, and there are challenges to overcome, such as incompatibility of materials, lack of understanding of the underlying physics, lack of suitable process parameters, and degradation of material properties. The methods used in this project to overcome these challenges are based on PBF (powder bed fusion) and DED (directed energy deposition) and can produce lightweight, complex geometry components that can operate in harsh environments. The process is expected to reduce lead times by 20%, produce 50% lighter parts, and be more resilient to supply chain disruptions. The project will be tested on rocket engines, marine engines, and cryogenic hydrogen tanks. It is expected to generate new standards, strengthen EU leadership, and contribute to sustainable transportation.

DISCO2030 is expected to generate a significant impact by paving the way for the creation of new dissimilar material joining and testing standards, strengthening the EU’s leadership in AM technologies, and increasing the EU’s resilience against global supply chain disruptions.

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

DISCO2030 combines the advantages of PBF and DED to create lightweight, complex geometry components and structures that can operate in harsh environments. The process is expected to reduce lead times by at least 20% compared to traditional manufacturing methods, such as die casting and brazing. It will also produce multi-material parts that are 50% lighter and 30% more performant than reference products.

The project will demonstrate its methods on three use-cases that are relevant to the European economy: a rocket engine, a marine engine, and a cryogenic hydrogen tank for the automotive sector. All components manufactured using the DISCO hybrid methods will be rigorously tested to industry standards.

TUM Chair of Materials Engineering of Additive Manufacturing has begun powder-directed energy deposition experiments using a plasma arc to join stainless steel 316L and copper alloy CuCr1Zr. This is a more challenging combination than nickel and copper alloys. The experiments started with depositing 316L powder on copper alloy build plates. After successfully depositing 316L on the copper build plate, trials for functional grading began. A wall with functional grading between copper alloy and stainless steel was built, and the material properties were characterized. In the upcoming months, experimentation with the nickel and copper alloy combination will also begin. In parallel to the welding experiments, the team is modeling the process in a suitable simulation environment. Building a model that can capture the distortions, temperature field, and residual stresses for additive manufacturing of functionally graded structures with directed energy deposition.

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 joining of dissimilar materials has become an important research topic in recent decades. Over 20,000 journal articles have been published on the topic since the 1970s. Early research focused on joining carbon, low alloy steels, stainless steel, and aluminum alloys. Recent progress in the development of novel materials, such as Inconel superalloys, ceramics, and polymers, is pushing the boundaries of the field. Several manufacturing technologies have been used for dissimilar material joining, including traditional mechanical joining, welding, solid-state joining, brazing and soldering, and adhesive bonding. The choice of joining method depends on the specific materials being joined, the desired properties of the joint, and the cost and complexity of the process. The development of new joining technologies is ongoing, as researchers seek to develop methods that are more efficient, reliable, and cost-effective.

DISCO2030 is a promising project that has the potential to revolutionize the way we manufacture complex components and structures. The project's findings could have a significant impact on the European economy and society and could help to make our transportation systems more sustainable and cost-effective.

Here are some of the key benefits of the DISCO2030 methods:
• Reduced lead times: The process is expected to reduce lead times by at least 20% compared to traditional manufacturing methods.
• Lighter and more performant parts: The process can produce multi-material parts that are 50% lighter and 30% more performant than reference products.
• Increased resilience to supply chain disruptions: The process is based on AM technologies, which are less dependent on imported materials and components.
• Potential for new standards: The project is expected to generate new standards for joining dissimilar materials, which could benefit the entire AM industry.
• Strengthened EU leadership: The project will help to strengthen the EU's leadership in AM technologies, which is a strategically important area for the European economy.
• Contribution to the European economy: The project is expected to contribute to the reinvention of the European aerospace, marine, and automotive sectors, which could create jobs and boost economic growth.

DISCO2030 Technical overview of the project