An automated and simplified design process has been determined for biomimetic lightweight structures. A toolset for a commercial 3D-CAD software has been developed, which allows a seamless workflow from the part design to the ALM pre-processing and post processing steps. It enables an automated bionic feature recognition based on a catalogue of parameterized structures, which was also developed in the frame of the project. A business plan has been developed for transfer to industrial applications.
The ICP atomization method was successfully transferred from standard Al alloys to high strength Al alloys. The high-strength AlSiSc alloy processed in the end of the first reporting period delivered superior mechanical properties and processability.The share of powder usable for ALM process was increased from 63% at the project start to 74%. In parallel small particle size fractions which are waste material, could be reduced by 10 %.
The ALM test rig has been developed and used to verify simulation models and optimize the laser beam profiles towards enhanced process stability and productivity. Overall it was possible to demonstrate that a productivity increase of 35% was achieved for the new high-strength AlSiSc material using innovative beam shaping optics.The successsful developments will increase the applicability of the process in the aviation industry, leading to more resource efficiency in aviation. An action plan has been developed in order to develop ALM parameter sets for highly productive and resource efficient ALM processes that can be commercialized in the future.
An in-line integrity system was developed to validate the quality of complex ALM parts directly after manufacturing. This allows to detect defects below the surface and to measure the outer geometry of the workpiece simultaneously. A business plan for the in-line ultrasonic detection of complex shaped components has been developed.
To be able to already check the integrity of an ALM part during the building process, an in-process integrity system based on the Strucutred Light 3D technology was developed. In the course of the project multiple technical solutions for in-service NDT methods have been evaluated. The most promising solutions are advanced ultrasonic testing as well as diffuse dome light inspection.
The overall applicability of ALM to the after sales supply chain has been explored, and new business models to reduce inventory, increase competiveness and increase market offering have been elaborated. The most promising ones were combined to a new concept, the Additive Manufacturing Marketplace. Based on this a new end-to-end process was developed, which unwraps a new way of handling the supply chain by introducing ALM as a niche in the current supply chain operations without replacing the existing end-to-end process.
Thermal Spraying has been found most promising for resource efficient and cost competitive repair of the new Al-based parts. Properties are only slightly below of those of the original material. Major advantages might be linked to the possible increase of the fracture properties of the repaired component.
The ICP spheroidization process has proven the capability to refurbish used ALM powder and enhancing its physical properties, thereby reducing the waste of powders following ALM production. It was shown that powders could be reused up to 18 times with only marginal effects on the porosity, hardness and tensile properties of the resulting ALM parts. An action plan has been developed to further investigate the ICP spheroidization technique with the ultimate goal to qualify the recycling method for the aerospace industry.
