Intelligent data-driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition processes

Project Information

INTEGRADDE

Grant agreement ID: 820776

DOI

10.3030/820776

Project closed

EC signature date 27 September 2018

Start date 1 October 2018

End date 31 March 2023

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced manufacturing and processing

Total cost

€ 16 999 328,75

EU contribution

€ 12 716 173,51

Coordinated by

ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE
Spain

Periodic Reporting for period 3 - INTEGRADDE (Intelligent data-driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition processes)

Reporting period: 2021-10-01 to 2023-03-31

Summary of the context and overall objectives of the project

INTEGRADDE Project stands for Intelligent data-driven pipeline for manufacturing metal parts through Direct Energy Deposition processes. INTEGRADDE proposes an integrated automation methodology for developing an end-to-end digital solution applied to the manufacturing of metal components by Additive Manufacturing (AM) in real manufacturing conditions through industrial-driven pilot lines. INTEGRADDE combines novel technologies along the product manufacturing workflow: topology optimisation algorithms for optimised design, multi-scale modelling providing feedback for optimising the set-up configuration process, automated hardware-independent process planning, online control, as well as distributed NDT and metrology for quality assurance. Finally, Artificial Intelligence models for assisting in the optimisation of new metal parts are being implemented.
Consortium is led by AIMEN Technology Centre and is made up of 26 European entities from 11 countries, including research and technology organizations, technology providers, system integrators, and end-users.
INTEGRADDE has achieved the following main innovations:
- An interoperable methodology implemented in different hardware layouts along the manufacturing chain.
- A Open Pilot Lines Network (AIMEN, CEA, IREPA, WEST) for boosting AM in other sectors and applications, as well as stimulating market uptake of the portfolio of technologies developed in the project. Access to the INTEGRADDE services can be found on the project website, https://opln.fundingbox.com/.
- Commissioning and deployment of industrial-showrooms (PRIMA, DGH, MX3D) validating the portfolio of technologies on different hardware configuration solutions.
- 5 industrial-driven pilot lines in aeronautics, construction, tooling, steel and automotive (LOIRETECH, MX3D, GKN, AMIII, CORDA end users).
A summary booklet showing the five demonstrators are available on the INTEGRADDE website: integraddeproject.eu/multimedia
Finally, overall project cross-sectional activities such as dissemination, exploitation, standardisation, and certification have been undertaken (FBA, BUREAU VERITAS & DIN).

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

In this third period INTEGRADDE project completed the following tasks:
-Definition and implementation of the cyber-secured Digital Thread (DT).
-Advise on the creation of new procedures for standardization and certification of manufactured parts by defining the current certification procedures.
-Process window development and collection of experimental data for the different pilot lines. Open datasets produced during the project are available as open repository: https://zenodo.org/record/5031586#.YYvC72DMI2w
-Multiphysics FEM-based simulation has been implemented and tested.
-Product engineering optimisation by combining simulation predictions, material characterization, process monitoring, and data analytics.
-Interoperable CAD/CAM system compatible with different hardware layouts as well as software tools.
-Implementation of real-time control strategies for LMD-p, LMD-w and WAAM processes.
-Software tools for multimodal data registration. Data analytics and knowledge-based systems.
-Integration of QIF standard to incorporate GD&T information in the DT.
-Implementation of inline/online/offline quality control methods and metrology.
-- Open Pilot Lines network and the launching of the Expression of Interest (EoI), published, offering a catalogue of services, provided free of charge, and aiming at EU companies to raise awareness among Metalworking companies in the AM of metal components.
- Deployment of technologies for manufacturing demonstrators.
LOIRETECH: https://youtu.be/CDr3dxCBq-0
MX3D: https://youtu.be/7iGil6i3hC0
AMIII: https://youtu.be/T_J8IbIphEU
CORDA: https://youtu.be/EekUfX9fF8s
GKN. https://youtu.be/f3C0WSDCNK8
INTEGRADDE has engaged in EU Dissemination & Exploitation Booster to strengthen the capacity of the project for disseminating and exploiting their research results. Also, a training plan covering the whole AM value chain has been implemented, as well as the definition of a guideline for certification of AM metal-based components and a standardization strategy.

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)

INTEGRADDE enhances environment, quality of life of European citizens and AM competitiveness:
- Innovation: tools, experience and know-how developed along INTEGRADDE enhances the innovation capacity through technology transfer impacting EU industry and academia.
- Competitiveness: project results strengthen INTEGRADDE industrial partners market positioning: commercialising innovative technology solutions that can significantly improve leadership and competitiveness of AM, efficient of manufacturing, lot size, design-freedom, etc. The impact expected for the industry and project results:
+ To increase reliability in AM processes by 40% and manufacturing speeds by 25%.
Reliability and time saving in the different fabrication stages were achieved. As an example, MX3D demonstrated a time reduction for WAAM in refitting CAD, tunning the process window, refining and generation of machine code.
+ To improve capacity to manufacture a good piece at first by 40% and in product quality by 40%.
Monitoring and automation of defect-detection operations allowed the improvements in the right first-time fabrication. Some examples of representative achievements are the porosity reduction in LOIRETECH due to the implementation of AM as fabrication process; the controls deployed in the AMIII, with NDT assessments after AM process (robotics + flash thermography); or the inline Metrology (3D scanning) providing a high accuracy dimensional control.
+ To reduce time to market by 25%. New certification schemes for metal parts printed in 3D.
Tight process control in LMD tool repair, through the application of correct process and control practices, ensures that repaired tools meet the required specifications and perform as expected. Monitoring LMD process parameters, ensures that they are within acceptable ranges and the use of 3D scanning improves, in terms of time and quality, LMD repairs and corrections to the repair process. MX3D demonstrated that the right process parameters window and printing file, in addition to the integrated software solutions along product lifecycle led to higher quality and cycle execution improvements.
+ Standardization roadmap by linking with current ISO/TC 261. INTEGRADDE project has stablished liaisons (ISO/TC 261/WG 2, SO/TC 261/WG 3, SO/TC 261/WG 4).
- Growth and jobs: INTEGRADDE contributes to create more and better high added-value jobs within the manufacturing industry. We have organized Open training, webinars and Certification Guidelines that allow gaining new relevant skills for the European workforce.
- Environmental: INTEGRADDE enables the integration of DED AM processes into current industrial production lines. With AM, waste is reduced to practically zero. INTEGRADDE is aligned with EU environmental challenges optimising sustainable production and efficiency.
- Contribution to EU Policies. INTEGRADDE initiative as flagship H2020 project aims an intelligent, sustainable, and inclusive growth and will became a leveraging effect on other sources of funding.
Address of the project public website: http://www.integraddeproject.eu. Finally, if you are a SME or a person interested in the INTEGRADDE Project you can reach us in: [e-mail]

Industrial-driven Pilot Lines

System Integrators

Integrated manufacturing solution for LMD and WAAM

Open Pilot Lines Network

Value chain covered by each Partner

INTEGRADDE dataflow