Description du projet
Des simulations avancées permettent de s’assurer que tout s’additionne bien dans la conception aérospatiale
La fabrication additive, également connue sous le nom d’impression 3D, a permis de raccourcir considérablement le cycle de conception et d’essai, de le rendre moins coûteux et de l’appliquer avec succès dans de nombreuses industries. Elle a également facilité la fabrication de pièces complexes de forme libre. La fabrication additive permet l’application successive de couches de matériaux à partir d’un fichier de conception assistée par ordinateur via une approche ascendante, plutôt que de retirer des matériaux d’un bloc via une approche descendante qui requiert un post-traitement beaucoup plus important. Le projet SUPERMODEL, financé par l’UE, permettra de développer des modèles avancés de l’évolution des caractéristiques microstructurales des alliages métalliques complexes lors de la fabrication additive de pièces pour l’industrie aérospatiale de l’UE. La combinaison de travaux expérimentaux et théoriques améliorera la capacité de prédiction des simulations, minimisant ainsi les défauts et rationalisant la vérification et la commercialisation des nouvelles conceptions.
Objectif
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.
Champ scientifique
- agricultural sciencesagriculture, forestry, and fisheriesagriculturegrains and oilseeds
- natural sciencescomputer and information sciencessoftwaresoftware applicationssystem software
- engineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturing
- natural sciencescomputer and information sciencessoftwaresoftware applicationssimulation software
- natural sciencesphysical sciencesopticslaser physics
Programme(s)
Régime de financement
CS2-RIA - Research and Innovation actionCoordinateur
CB21 6AL Cambridge
Royaume-Uni