PROGRESS BEYOND THE STATE OF THE ART
1. MATERIAL: controlling material properties at nano-level for properties on demand;
We will create functionally graded (multi)materials, by controlling the two main factors governing the material properties: the chemical composition and the thermal cycle. Functionally graded materials will be developed, whereby desired properties will be created at specific locations a) by compositional grading, altering the chemical composition of the melt pool by adding different wires and b) by adjusting the deposition conditions. Topology optimisation methods will enable us to manufacture "properties on demand" in the graded structure.
2. PROCESS: high throughput WAAM for multimaterial deposition;
High WAAM productivity will be achieved by transferring novel high throughput concepts to WAAM and developing multiple wire deposition systems. The productivity will increase from typically 2 kg/h to 5 kg/h, further doubling when a dual robot configuration is used. Heating strategies will be applied to mitigate distortion by redistribution of stresses. Cryogenic cooling will be used to control distortions and create certain microstructures. It will also increase production rates by reducing the inter-pass times. Non-destructive inspection devices will be integrated in the manufacturing line and coupled with an adaptive control system to allow real-time adjustment of process parameters and avoid defects.
3. SYSTEM: WAAM graded structures becoming “business as usual” for life cycle benefits;
We will pair the unique possibilities offered by WAAM in terms of data recording with state-of-the-art detection methods to develop an in-line contactless inspection system for WAAM. Such a system will ensure first time right quality and facilitate qualification. A comparative LCA will reveal the sustainability and cost benefits of WAAM grading. We will also develop qualification roadmaps for all WAAM produced components, to facilitate the adoption of WAAM as industry practice.
EXPECTED RESULTS:
• WAAM-as-a-service;
• WAAM equipment, including (multimaterial) robotic deposition and cryogenic cooling equipment;
• WAAM wire materials;
• WAAM graded products (demonstrators) – followed by technology roll-out within the organisations of the involved end-users, to unlock massive financial and material savings.
POTENTIAL IMPACTS:
The innovation work performed in Grade2XL will cut lead times by up to 96%, reduce material use by up to 65% and unlock savings estimated at 118 Million euro by 2030.
As our selection of challenging applications will demonstrate, the multimaterial WAAM will reduce cost by 35% to 85% and lead times by 67% to 96 %, and enable material savings of 30% to 65% overall. Functional grading will deliver a significant impact on the use of expensive materials, with savings of 81% to 94%. With the ability of WAAM to regenerate components back to the original shape through local, on-site repair, the maritime industry will be able to reshore jobs from China and further limit the environmental impact of the marine operations. We will also reach out to groups who can foster the creation of new value chains. Although fully automated, our approach on advancing WAAM will preserve current jobs and offer training for the future generation of WAAM engineers.
