Deliverables
Each ESR should aim, during his/her 3 year PAM^2 training period, to publish at least 2 journal papers and 2 conference papers; the conference papers will also be presented (either as a poster or an oral presentation) by the ESR.
A public and interactive website will be made. The PAM^2 website will be used to publicly post the PAM^2 ESR vacancies and the PAM^2 dissemination activities (e.g. publications from open access sources or from journals that allow post-print archiving, press releases, YouTube videos, etc.) and announce relevant events. For example a plan for the public lectures will be made by M6 and published on the website and updated subsequently. There will also be an interactive part on the website, where anyone interested in the project can make comments or ask questions. The more popular part of the website will also provide access to the more in-depth research results, as far as these are in the public domain. Alternate ESRs will be in charge of answering the questions (for a month at a time). This will be coordinated by the WP5 leader (TUD).
During the network-wide workshops, hands-on training will be given in groups. Each group will work on a specific AM example that they carry with them from workshop to workshop, from computational design to product assessment. As a training for the students and as an outreach activity, they will document each hands-on session with a YouTube movie. This will form part of a number of movies documenting the whole production process. This series of movies, gradually released depending on the workshop schedule, can be used to train and inform the general public, but also to complement theoretical AM training given in the post-PAM^2 period. In addition, this series can form a positive ‘competition’ between the different ESR groups, where they can compete for the most views to their movie series. This competitive aspect will ensure that the quality of the movies is high and that the public is encouraged to view them. The ESRs in the group will take turns in making the movie. These movies will include references to in-depth information, e.g. PAM^2 papers published in open access journals, and thus act as an attractive portal to the scientific outcome of the program.
In-process high speed measurements of the melt pool (KU Leuven), post-process metrology results including post-AM CT (UNIPD) and TEM/SEM investigations of cross sections through parts, will be linked to understand the relationship between the processing parameters of the AM test cases and the internal and external quality of these parts. Understanding this relationship between processing parameters and quality of the part is the first step towards the possibility for in-process control.
Optical and x-ray methods will be reviewed, selected and further developed for the post-process measurement of the internal and external form of AM parts. In the optical case (UNOTT), modelling of the instrument response will be used to reduce systematic errors and improve instrument bandwidth (therefore, allowing the complex structures produced by AM to be measured effectively). In the X-ray CT case (UNIPD), standard methods for measuring AM parts and for estimating measurement uncertainties will be developed, and good practice guidance will be produced. The most appropriate post-process instrumentation and its use for the end-user case studies will be selected.
KIT will develop a post-AM laser-based finishing process for the reduction of surface roughness, control of surface hardness, surface wettability and the enhancement of edge quality. In addition, KU Leuven will develop an in-situ subtractive laser-based process that can be combined with the additive process to increase part accuracy, reduce part roughness and porosity by a factor of 10-16. A report of how the in-process and post-AM laser-based processes improve the surface properties of the AM part will be written.
Advanced computational design tools, which enable effective 3D design of competitive precision components to be produced by AM, are developed. The newly developed topology optimisation techniques will target precision designs which are “AM ready” and hence do not require expensive re-engineering to make them suited for AM. The elimination or major reduction of these re-engineering steps will reduce costs, improve time-to-market and lead to designs with superior final precision and performance. PAM^2 gives the unique setting to build upon both AM process knowledge and new AM process models. The latter will be thoroughly integrated in topology optimisation tools for precision components. For this purpose, reduced-order AM process models will be developed which also provide the paramount sensitivity information. Computational modelling techniques will be developed in collaboration with the researchers in Task 1.2 and validated via collaboration with WP2 and WP3
Process knowledge from WP2 partners and measurements from WP3 partners are used for setting up simulations and for calibrating the numerical process models. A coupled multi-scale thermo-metallurgical-mechanical model for simulating precision additive manufacturing is developed by using a local model for simulating laser-material interaction and melting/solidification processes and a global thermo-mechanical model for evaluating residual stresses and deformations. Smart, advanced modelling techniques to reduce computation time to an acceptable range while preserving accuracy are implemented and statistical methods for a robust calibration of the numerical models are applied. In addition, a thermo-microstructural-mechanical model of secondary processing of PAM^2 parts is developed through fast and accurate thermal, microstructural and mechanical solvers capable of handling large computational domains. The evolution of part porosities and resulting material properties is tracked by a developed thermal-microstructural model and constitutive modelling of materials to predict residual stresses and deformations is implemented.
The thermo-microstructural-mechanical models for precision AM and secondary processing (Task 1.2) are combined to simulate the entire precision additive manufacturing process chain. Residual stresses, deformations and mechanical-microstructural properties of parts designed in Task 1.1 are predicted and the results are validated in collaboration with WP2 and WP3 partners. Subsequent to successful validation of working models, numerical model based process optimisation and process uncertainty quantification of both SLM and secondary process are performed to better control the characteristics of the parts produced in PAM^2 as well as to increase the process knowledge base.
2 summer schools will be organised: Summer School 1, the Leadership course at NP TEC (M18) is part of D4.2. Summer School 2, covering an in-depth AM study takes place at UNIPD (M30) and consists of a technical training (3.5 days) given by senior researchers from all beneficiaries and partners to ensure an in-depth examination of all aspects of AM. The programme will be structured in 7 courses (1/2 day each) on the following topics: (1) General introduction to AM (review and more in-depth technical training on contents of Workshop 1); (2) Advanced system design, specs and computational design; (3) Advanced process modelling; (4) Manufacturing and process control; (5) Introduction to post-processing; (6) Metrology for AM; (7) Introduction to geometrical and functional assessment. Also a tour of the facilities and a Poster session is foreseen.
A special symposia will be organised at the euspen international conference (http://www.euspen.eu/) in June 2019 and June 2020. This symposium will be jointly organised with chairpersons from each beneficiary/partner (for example 4 sessions with 3 chairpersons each) who will be in charge of inviting keynote speakers and chairing the session.
A hybrid optical system will be developed, which combines a vision system with a focus variation system. The hybrid system will be capable of measuring the presence of defects and then measuring the topography of such defects. The system will be developed as a collaboration between UNOTT and ALICON. The prototype in-process instrument will characterized and a report will be written.
Publications
Author(s): Ann Witvrouw
Published in: Special Interest Group Meeting : Quality Control for Additive Manufacturing, Issue 23-24 January 2017, 2017
Author(s): Jitka Metelkova, Yanis Kinds, Charlotte de Formanoir, Ann Witvrouw, Brecht Van Hooreweder
Published in: Solid Freeform Fabrication Symposium 2019, Issue 2019, 2019
Author(s): R. Ranjan, Y. Yang, C. Ayas, M. Langelaar, F. Van Keulen
Published in: Dimensional Accuracy and Surface Finish in Additive Manufacturing, October 2017, 2017
Author(s): Mirko Sinico, Evelina Ametova, Ann Witvrouw, Wim Dewulf
Published in: 2018 ASPE and euspen Summer Topical Meeting - Advancing Precision in Additive Manufacturing, Issue Volume 69, 2018
Author(s): Mandaná Moshiri
Guido Tosello
Sankhya Mohanty
Published in: EUSPEN´s 18th International Conference & Exhibition, 2018
Author(s): R. Ranjan, C. Ayas, M. Langelaar, F. Van Keulen
Published in: 2018 ASPE and euspen Summer Topical Meeting: Advancing Precision in Additive Manufacturing, Issue Volume 69, 2018, Page(s) 29-34
Author(s): Ann Witvrouw, Jitka Metelkova, Rajit Ranjan, Mohamad Bayat, David De Baere, Mandaná Moshiri, Guido Tosello, Juliana Solheid, Amal Charles, Steffen Scholz, Markus Baier, Simone Carmignato, Petros Stavroulakis, Amrozia Shaheen, Lore Thijs
Published in: 2018 ASPE and euspen Summer Topical Meeting 'Advancing Precision in Additive Manufacturing', Issue Volume 69, 2018, Page(s) 18-23
Author(s): Markus Baier
Filippo Zanini
Enrico Savio
Simone Carmignato
Published in: Conference Proceedings 18th International Conference & Exhibition, Issue 18, 2018, Page(s) 445-446
Author(s): Markus Baier
Published in: Proc. 8th ICT conference, Issue 8, 2018, Page(s) 208-209
Author(s): Juliana dos Solheid
Hans Jürgen Seifert
Wilhelm Pfleging
Published in: EUSPEN's 18th International Conference & Exhibition, 2018
Author(s): Mandaná Moshiri
Guido Tosello
Sankhya Mohanty
Published in: 2018
Author(s): Aditi Thanki
Louca Goosens
Raya Mertens
Gabriel Probst
Wim Dewulf
Ann Witvrouw
Shoufeng Yang
Published in: 2019
Author(s): Umberto Paggi, Lore Thijs, Brecht Van Hooreweder
Published in: 3rd Workshop on Metal Additive Manufacturing, Issue Annual, 2018
Author(s): Amrozia Shaheen, Petros Stavroulakis, Richard Leach
Published in: 2018
Author(s): Amal Charles Prashanth, Ahmed Elkaseer, Tobias Müller, Lore Thijs, Maika Torge, Veit Hagenmeyer, Steffen Scholz
Published in: World Congress on Micro and Nano Manufacturing 2018, Issue 2, 2018, Page(s) 327-330
Author(s): Amal Charles Prashanth, Ahmed Elkaseer, Tobias Mueller, Lore Thijs, Veit Hagenmeyer, Steffen Scholz
Published in: 2018 ASPE and euspen Summer Topical Meeting: Advancing Precision in Additive Manufacturing, Issue Volume 69, 2018, Page(s) 83-88
Author(s): Rajit Ranjan
Yabin Yang
Can Ayas
Matthijs Langelaar
Fred van Keulen
Published in: 2018
Author(s): Petros Stavroulakis, Patrick Bointon, Danny Sims-Waterhouse, Amrozia Shaheen, Samanta Piano, Richard Leach
Published in: 2017
Author(s): Juliana S. Solheid, Hans. J. Seifert, Wilhelm Pfleging
Published in: Materials Science and Engineering Congress 2018, 2018
Author(s): David De Baere, Emilie Hørdum Valente, Sankhya Mohanty, Jesper Henri Hattel
Published in: euspen's 18th International Conference & Exhibition, 2018
Author(s): Mohamad Bayat, Sankhya Mohanty, Jesper H Hattel
Published in: EUSPEN 18th International Conference & Exhibition, 2018
Author(s): M Bayat, D De Baere, Sankhya Mohanty, J H Hattel
Published in: Proceeding of 12th International Seminar on Numerical Analysis of Weldability , 2018
Author(s): Mohamad Bayat; Sankhya Mohanty; Jesper H. Hattel
Published in: 2018
Author(s): Subbareddy Darukumalli
Teguh Santoso
Wahyudin P. Syam
Franz Helmli
Richard Leach
Published in: 19th International Conference Proceedings: Bilbao 2019, 2019
Author(s): Jitka Metelkova
Yannis Kinds
Karolien Kempen
Charlotte de Formanoir
Ann Witvrouw
Brecht Van Hooreweder
Published in: 4th Workshop on Metal Additive Manufacturing, Issue Annual, 2019
Author(s): Umberto Paggi, Rajit Ranjan, Lore Thijs, Can Ayas, Matthijs Langelaar, Fred van Keulen, Brecht Van Hooreweder
Published in: 4th Workshop on Metal Additive Manufacturing, Issue Annual, 2019
Author(s): Mirko Sinico, Rajit Ranjan, Mandaná Moshiri, Can Ayas, Matthijs Langelaar, Ann Witvrouw, Fred van Keulen, Wim Dewulf
Published in: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium, Issue 2019, 2019, Page(s) 1921-1951
Author(s): Jitka Metelkova, Charlotte de Formanoir, Han Haitjema, Ann Witvrouw, Wilhelm Pfleging, Brecht Van Hooreweder
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Mirko Sinico, Ann Witvrouw, Wim Dewulf
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Amal Charles, Ahmed Elkaseer, Mahmoud Salem, Lore Thijs, Steffen Scholz
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Umberto Paggi, Mirko Sinico, Lore Thijs, Wim Dewulf, Brecht Van Hooreweder
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Umberto Paggi, Rajit Ranjan, Lore Thijs, Can Ayas, Matthijs Langelaar, Fred Van Keulen, Brecht Van Hooreweder
Published in: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium 2019, Issue 2019, 2019, Page(s) 1626-1640
Author(s): Mohamad Bayat, Christopher G. Klingaa, Sankhya Mohanty, Jesper H. Hattel
Published in: EUROMAT 2019, Issue 2019, 2019
Author(s): Rajit Ranjan, Matthijs Langelaar, Can Ayas, Fred Van Keulen
Published in: SIM-AM conference 2019, Issue 2019, 2019
Author(s): Markus Baier, Mirko Sinico, Umberto Paggi, Ann Witvrouw, Lore Thijs, Wim Dewulf,
Simone Carmignato
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): dos Santos Solheid, Juliana; Elkaseer, Ahmed; Wunsch, Torsten; Charles, Amal; Seifert, Hans Jürgen; Pfleging, Wilhelm; Klotzbach, Udo [Hrsg.]; Kling, Rainer [Hrsg.]; Watanabe, Akira [Hrsg.]
Published in: Laser-based Micro- and Nanoprocessing XIV, Issue 11268, 2020
DOI: 10.5445/ir/1000117583
Author(s): Baier, Markus; Sinico, Mirko; Paggi, Umberto; Witvrouw, Ann; Thijs, Lore; Dewulf, Wim; Carmignato, Simone
Published in: Conference Proceedings: Advancing Precision in Additive Manufacturing 2019, Issue 1, 2019
Author(s): Shaheen A., Piano S., Sims-Waterhouse D., Bointon P., Leach R. K
Published in: Conference Proceedings : Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Lokesh Chandrabalan, Emanuele Matoni, Martina Malarco, Eugenio Del Puglia, Luca Ammannato, Simone Carmignato
Published in: Conference Proceedings: Advancing Precision in Additive Manufacturing 2019, Issue 2019, 2019
Author(s): Jitka Metelkova, Yannis Kinds, Karolien Kempen, Charlotte de Formanoir, Ann Witvrouw, Brecht Van Hooreweder
Published in: Additive Manufacturing, Issue 23, 2018, Page(s) 161-169, ISSN 2214-8604
DOI: 10.1016/j.addma.2018.08.006
Author(s): Juliana dos Santos Solheid, Hans Jürgen Seifert, Wilhelm Pfleging
Published in: Procedia CIRP, Issue 74, 2018, Page(s) 280-284, ISSN 2212-8271
DOI: 10.1016/j.procir.2018.08.111
Author(s): David De Baere, Mohamad Bayat, Sankhya Mohanty, Jesper Hattel
Published in: Procedia CIRP, Issue 74, 2018, Page(s) 87-91, ISSN 2212-8271
DOI: 10.1016/j.procir.2018.08.035
Author(s): Mandaná Moshiri
Stefano Candeo
Simone Carmignato
Snakhya Mohanty
Guido Tosello
Published in: Journal of Manufacturing and Materials Processing, Issue 3/4, 2019, Page(s) 85, ISSN 2504-4494
DOI: 10.3390/jmmp3040085
Author(s): Amal Charles Prashanth, Ahmed Elkaseer, Lore Thijs, Veit Hagenmeyer, Steffen Scholz
Published in: Applied Sciences, Issue Volume 9, Issue 6, 2019, ISSN 2076-3417
Author(s): Anton du Plessis, Stephan G. le Roux, Jess Waller, Philip Sperling, Nils Achilles, Andre Beerlink, Jean-François Métayer, Mirko Sinico, Gabriel Probst, Wim Dewulf, Florian Bittner, Hans-Josef Endres, Marian Willner, Ágota Drégelyi-Kiss, Tomas Zikmund, Jakub Laznovsky, Jozef Kaiser, Pascal Pinter, Stefan Dietrich, Elena Lopez, Oliver Fitzek, Porebski Konrad
Published in: Additive Manufacturing, Issue 30, 2019, Page(s) 100837, ISSN 2214-8604
DOI: 10.1016/j.addma.2019.100837
Author(s): Mohamad Bayat, Sankhya Mohanty, Jesper Henri Hattel
Published in: International Journal of Heat and Mass Transfer, Issue 139, 2019, Page(s) 95-114, ISSN 0017-9310
DOI: 10.1016/j.ijheatmasstransfer.2019.05.003
Author(s): Mohamad Bayat, Sankhya Mohanty, Jesper Henri Hattel
Published in: International Journal of Heat and Mass Transfer, Issue 139, 2019, Page(s) 213-230, ISSN 0017-9310
DOI: 10.1016/j.ijheatmasstransfer.2019.05.017
Author(s): Mohamad Bayat, Aditi Thanki, Sankhya Mohanty, Ann Witvrouw, Shoufeng Yang, Jesper Thorborg, Niels Skat Tiedje, Jesper Henri Hattel
Published in: Additive Manufacturing, Issue 30, 2019, Page(s) 100835, ISSN 2214-8604
DOI: 10.1016/j.addma.2019.100835
Author(s): W. Gao, H. Haitjema, F.Z. Fang, R.K. Leach, C.F. Cheung, E. Savio, J.M. Linares
Published in: CIRP Annals, Issue 68/2, 2019, Page(s) 843-866, ISSN 0007-8506
DOI: 10.1016/j.cirp.2019.05.005
Author(s): R.K. Leach, D. Bourell, S. Carmignato, A. Donmez, N. Senin, W. Dewulf
Published in: CIRP Annals, Issue 68/2, 2019, Page(s) 677-700, ISSN 0007-8506
DOI: 10.1016/j.cirp.2019.05.004
Author(s): Solheid, Juliana; Mohanty, Sankhya; Bayat, Mohamad; Wunsch, Torsten; Weidler, Peter G.; Seifert, Hans J.; Pfleging, Wilhelm
Published in: Journal of Laser Applications, Issue 1, 2020, ISSN 1042-346X
DOI: 10.5445/IR/1000104497
Author(s): Jitka Metelkova, Daniel Ordnung, Yannis Kinds, Ann Witvrouw, Brecht Van Hooreweder
Published in: Procedia CIRP, Issue 94, 2020, Page(s) 266-269, ISSN 2212-8271
DOI: 10.1016/j.procir.2020.09.050
Author(s): MIRKO SINICO, RAJIT RANJAN, MANDANÁ MOSHIRI, CAN AYAS, MATTHIJS LANGELAAR, FRED VAN KEULEN, WIM DEWULF AND ANN WITVROUW
Published in: Mikroniek, Issue Issue 5, 2019, Page(s) 23-28, ISSN 0026-3699
Author(s): Petros Stavroulakis, Danny Sims-Waterhouse, Amrozia Shaheen, Sofia Catalucci, Patrick Bointon, Elodie Doyen, Yael Bis Kong, Yorgos Tzimiropoulos, Richard Leach
Published in: Intelligent Systems and Applications - Proceedings of the 2018 Intelligent Systems Conference (IntelliSys) Volume 2, Issue 869, 2019, Page(s) 1273-1281
DOI: 10.1007/978-3-030-01057-7_96
