Project description DEENESFRITPL Advanced simulations make sure it all adds up when it comes to aerospace designs Additive manufacturing, also known as 3D printing, has made the design and testing cycle much shorter, less expensive, and successful in many industries. It has also made manufacturing of complex free-form parts much easier. Additive manufacturing enables the successive application of layers of materials from a computer-aided design file in a bottom-up approach, rather than removing materials from a block in a top-down approach that requires much more post-processing. The EU-funded SUPERMODEL project will develop advanced models of the evolution of microstructural characteristics in complex metal alloys during additive manufacturing of parts for the EU aerospace industry. Combined experimental and theoretical work will improve the predictive ability of simulations, minimising defects and streamlining the verification and commercialisation of new designs. Show the project objective Hide the project objective Objective SUPERMODEL will (1) develop a state-of-the-art microstructure evolution model for blown powder laser metal deposition processing and post-processing of multiple super alloys (including Inconel 718) that can predict grain sizes; orientation and texture; phase composition (including precipitation & particle size); and defect (pores and lack of fusion) distributions; (2) link the microstructure model to part-level (global) thermo-mechanical LMD process simulations to enable a direct coupling between continuum-scale stress-strain behaviour and the evolution of microstructural internal state variables; (3) validate the computational models through iterative, detailed and comprehensive experimental test programmes including in-line monitoring of melt pools, thermal transients, stresses and deformation; post-build, 3D scanning of part distortions; metallographic examination and CT scanning; and (4) demonstrate the predictive powder of the model on a complex part (curved substrate with angular features) incorporating two different superalloys with runtimes less than 5 days. This will be achieved through an ambitious numerical-experimental procedure leveraging design-of-experiments methodologies and iterative feedback between modelling activities and testing to develop a robust software system.SUPERMODEL contributes to the aims of the Clean Sky Engines ITD by providing experimental data and simulation tools that will enhance the reliability of additive manufacturing technology, thereby streamlining LMD part certification and qualification, minimises experimental trial-and-error along the way. SUPERMODEL will therefore make progress towards achieving the EC goal of moving from “Modelling-for-Industry” to “Modelling-by-Industry” which means shifting effort from laboratory- and RTO-centred activities to helping industry equip itself with advanced simulation tools. Fields of science agricultural sciencesagriculture, forestry, and fisheriesagriculturegrains and oilseedsnatural sciencescomputer and information sciencessoftwaresoftware applicationssystem softwareengineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturingnatural sciencescomputer and information sciencessoftwaresoftware applicationssimulation softwarenatural sciencesphysical sciencesopticslaser physics Programme(s) H2020-EU.3.4. - SOCIETAL CHALLENGES - Smart, Green And Integrated Transport Main Programme H2020-EU.3.4.5.5. - ITD Engines Topic(s) JTI-CS2-2018-CfP08-ENG-02-09 - Development and verification of microstructure, residual stress and deformation simulation capability for additive free-form deposition using multiple superalloys Call for proposal H2020-CS2-CFP08-2018-01 See other projects for this call Funding Scheme CS2-RIA - Research and Innovation action Coordinator TWI LIMITED Net EU contribution € 739 375,00 Address Granta park great abington CB21 6AL Cambridge United Kingdom See on map Region East of England East Anglia Cambridgeshire CC Links Contact the organisation Opens in new window Website Opens in new window Participation in EU R&I programmes Opens in new window HORIZON collaboration network Opens in new window Other funding € 0,00
