Periodic Reporting for period 2 - Grade2XL (Application of Functionally Graded Materials to Extra-Large Structures)
Periodo di rendicontazione: 2021-09-01 al 2023-02-28
Grade2XL will deliver a 3D-printing method for high-performance, multi-material large structures.
Large engineering structures like turbines, bridges, or industrial machinery are still manufactured by traditional processes such as forging and casting. These processes do not allow engineers to control material properties locally in order to achieve anti-corrosion or hardness functions only at the exposed or loaded locations in the structure. Grade2XL project will tap into the potential of wire arc additive manufacturing. This method combines high printing rates with the ability to control material properties down to the nanoscale, enabling the design of strong and durable engineering structures. The project is expected to deliver devices of superior quality and performance, cut lead times by up to 96 %, and unlock massive cost savings for the maritime and energy industries. The following objectives were set to structure our ambitions:
Objective 1: Develop functionally graded materials and a high throughput WAAM process for multi-material deposition with in-line, contactless inspection features.
Objective 2: Demonstrate the added value of local control of material properties with WAAM to reduce the material use and lifecycle costs of large-scale manufacturing by at least 35%.
Objective 3: Roll-out WAAM as an economically viable and sustainable alternative to the conventional technologies – delivering the Industrial 4.0 revolution.
Large engineering structures like turbines, bridges, or industrial machinery are still manufactured by traditional processes such as forging and casting. These processes do not allow engineers to control material properties locally in order to achieve anti-corrosion or hardness functions only at the exposed or loaded locations in the structure. Grade2XL project will tap into the potential of wire arc additive manufacturing. This method combines high printing rates with the ability to control material properties down to the nanoscale, enabling the design of strong and durable engineering structures. The project is expected to deliver devices of superior quality and performance, cut lead times by up to 96 %, and unlock massive cost savings for the maritime and energy industries. The following objectives were set to structure our ambitions:
Objective 1: Develop functionally graded materials and a high throughput WAAM process for multi-material deposition with in-line, contactless inspection features.
Objective 2: Demonstrate the added value of local control of material properties with WAAM to reduce the material use and lifecycle costs of large-scale manufacturing by at least 35%.
Objective 3: Roll-out WAAM as an economically viable and sustainable alternative to the conventional technologies – delivering the Industrial 4.0 revolution.
In WP1 coupons were produced for six (out of eight) demonstrator cases. The material characterization tests were conducted to evaluate the material properties in relation to the process conditions and the end-user requirements. Where these were not met, alternative combinations were proposed and tested. A novel, coupled thermo-mechanical and multi-material Topology Optimization algorithm was developed.
The Super Active Wire Process (S-AWP) was extensively tested and optimized in WP2. The deposition rate reached and even exceeded 5kg/h per robot for the stainless steels. These result give confidence in achieving the ambitious targets. An in-line monitoring system was developed and installed in both printing centres. The system is currently being optimized for multi-material printing. Efforts are currently focused on correlating this system with the non-destructive inspection technologies developed in WP3. A novel water-cooled torch designs that reduce the temperature build-up during deposition was developed and tested, the cooling system supports the increase in productivity. The cooling system and the MaxQ in-line monitoring system will be commercialized within the project.
In WP3 all information regarding the inspection requirements has been gathered. An experimental campaign has been organized to test the in-line inspection systems, and an other will follow in the project time-lime. The first test results are very promising.
Printing strategies were defined for all demonstrators and documented in a dedicated deliverable(report), in WP 4. The printing of the first two demonstrators 'A-2b Holding Ring' and 'B-1 Bathtub mold' started and are almost finished. The printing schedule, machining and testing for all other demonstrators is planned. The pre-production phase has been completed for four (out of eight) demonstrators cases.
In WP5 the material datasheets for the demonstrator cases was completed. The test results available so far have been included in the associated Material Data Sheet, which will be finalized after the demonstrator testing is completed.
The preliminary LCA and LCC carried out in WP 6 showed that products manufactured with WAAM performed environmentally and economically better than conventional manufacturing. More data is now being collected to complete the LCA and LCC by the end of the project.
WP7 has experienced problems due to the corona crisis and the restrictions for live events. Efforts were made to build an active on-line presence. A two-monthly webinar has been established. The roadshow has started in the second half of the project. In 2022 the project partners represented Grade2XL on numerous events.
The Super Active Wire Process (S-AWP) was extensively tested and optimized in WP2. The deposition rate reached and even exceeded 5kg/h per robot for the stainless steels. These result give confidence in achieving the ambitious targets. An in-line monitoring system was developed and installed in both printing centres. The system is currently being optimized for multi-material printing. Efforts are currently focused on correlating this system with the non-destructive inspection technologies developed in WP3. A novel water-cooled torch designs that reduce the temperature build-up during deposition was developed and tested, the cooling system supports the increase in productivity. The cooling system and the MaxQ in-line monitoring system will be commercialized within the project.
In WP3 all information regarding the inspection requirements has been gathered. An experimental campaign has been organized to test the in-line inspection systems, and an other will follow in the project time-lime. The first test results are very promising.
Printing strategies were defined for all demonstrators and documented in a dedicated deliverable(report), in WP 4. The printing of the first two demonstrators 'A-2b Holding Ring' and 'B-1 Bathtub mold' started and are almost finished. The printing schedule, machining and testing for all other demonstrators is planned. The pre-production phase has been completed for four (out of eight) demonstrators cases.
In WP5 the material datasheets for the demonstrator cases was completed. The test results available so far have been included in the associated Material Data Sheet, which will be finalized after the demonstrator testing is completed.
The preliminary LCA and LCC carried out in WP 6 showed that products manufactured with WAAM performed environmentally and economically better than conventional manufacturing. More data is now being collected to complete the LCA and LCC by the end of the project.
WP7 has experienced problems due to the corona crisis and the restrictions for live events. Efforts were made to build an active on-line presence. A two-monthly webinar has been established. The roadshow has started in the second half of the project. In 2022 the project partners represented Grade2XL on numerous events.
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.
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.