The project has delivered:
• A detailed set of material properties (results from tensile tests, low cycle fatigue, fatigue crack growth tests) which forms part of the aerospace qualification route
• Software and tools for repair characterisation (Canadian partners), feeding into deposition process planning
• A novel method of very accurately measuring melt-pool temperature in situ (Canadian partners) which can be used to validate process models and simulations
• Thermo-mechanical models – empirical (European partners) and simulations of melt-pool, powder-stream and part microstructure (Canadian partners)
• Process planning modules for each individual system to be used for part repair (all partners)
• Design optimisation module (European partners), which produces a set of optimised designs for objectives of performance, mechanical functionality and ease of manufacture / repair
• Evaluation of the project work for typical aerospace repairs
The European exploitable results are:
1+2. Robust parameter set and deposition parameters for Titanium powder on ECN equipment and for Inconel on USFD equipment. These results are owned by ECN and USFD respectively, who will use them in consultancy with industrial companies. After consultation, it can be exploited by companies engaged in aerospace repair or metallic component manufacture in the aerospace industry, as well as for refurbishment of castings. The expected impact is to reduce the experimental time required to determine repair parameters, and to increase confidence in the material condition of the AM material and the interface zone. This will help accelerate the take-up of AM in aerospace and in the repair market, increasing component lifetimes and reducing waste.Additional industries targeted by USFD include nuclear and oil and gas, as their deposition cell can deposit parts over 1 cubic metre.
3. Design optimisation rules for AM. This result is owned by GKN who will licence the result to their component manufacturers. As 80% of key design decisions are taken during the concept phase, it is critical to include AM-specific rules to take full advantage of its benefits during manufacture or access / material requirements during repair.
4. Modelling and design software modules for AM. This result is owned by DPS who plan to sell it as a service. It is targeted at OEMs and SMEs with AM capability; benefits include the ability to simulate distortion and to compensate. The services will be promoted by DPS through their sales force, to their clients.
5. Database of AM material properties. This result is owned by all the partners. Normalised data will be published, promoted through partner dissemination channels and shared with stakeholders such as the EU RM-platform. The target market is users of AM equipment and component designers. The database will increase confidence in the use of AM for components and for repair and will provide material data for AM-material and for the interface region. Currently, there is not a lot of ‘open’ data available; work tends to be carried out piecemeal, to different standards / protocols and to remain the property of the organisations paying for the work
6. Robotic directed energy deposition (DED) process-planning tool. This is owned by USFD and will be available within 12-18 month of the end of the project. It will be provided to companies as a service.
