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Application of Functionally Graded Materials to Extra-Large Structures

CORDIS provides links to public deliverables and publications of HORIZON projects.

Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .

Deliverables

Documents, reports (15)
Initial dissemination and exploitation plan (opens in new window)

A report of the first dissemination and exploitation plan, to be updated throughout the project.

Comparative LCA and LCC of the developed technology (opens in new window)

A quantified assessment of the life cycle environmental impacts and life cycle costs published as a report. Data may be sensitive and the report is considered confidential unless partners agree to publish.

"""Best practices"" for WAAM manufacturing" (opens in new window)

Document describing best practices for WAAM manufacturing.

Coaching sessions for SMEs (I-2) (opens in new window)

This deliverable will consist of reports on the coaching sessions delivered during the WAAM Experience Days and the Roadshow

Coaching sessions for SMEs (I-1) (opens in new window)

This deliverable will consist of reports on the coaching sessions delivered during the WAAM Experience Days and the Roadshow.

Final dissemination and exploitation plan (opens in new window)

The final plan gives an overview of communication, dissemination and exploitation achieved within the project, as well as of the outreach activities to be sustained beyond the lifetime of the project.

List of available guidelines (opens in new window)

Document compiling the identified guidelines found relevant for the application cases investigated

Preliminary LCA and LCC (opens in new window)

Selecting products/technologies to be compared with the new technology. A preliminary LCA and LCC report that can form input to environmental and costs considerations during the technology development. Contains also preliminary eco-efficiency indicators and indicators for circularity of materials.

Coaching sessions for SMEs (P) (opens in new window)

This deliverable will consist of reports on the coaching sessions delivered during the WAAM Experience Days and the Roadshow.

Qualification roadmaps (opens in new window)

Document describing the qualification steps for the application cases.

Comparative LCA and LCC of the developed technology (F) (opens in new window)

New deliverable ‘Comparative LCA and LCC of the developed technology (F)’. A quantified assessment of the life cycle environmental impacts and life cycle costs published as a report, with all data from the finished Demonstrators included. Data may be sensitive and the report is considered confidential unless partners agree to publish.

Coaching sessions for SMEs (F) (opens in new window)

This deliverable will consist of reports on the coaching sessions delivered during the WAAM Experience Days and the Roadshow.

Public report on WAAM demonstrators (opens in new window)

This deliverable will present the results of the demonstration activities in WP4 in a generalised fashion, highlighting relevance for a wider spectrum of applications.

Intermediate dissemination and exploitation plan (opens in new window)

Intermediate report on the communication dissemination and exploitation plan to be used in EC progress report

Public database on material properties and processing parameters (opens in new window)

The deliverable will include all experimental data, made available as public database.

Websites, patent fillings, videos etc. (5)
Final communication material (opens in new window)

This deliverable consists of the final project website, with easily accessible results, allowing further exploitation beyond the project. A final video of two minutes will be produced by M2i and distributed by EMC2 and M2i via both specialised and generic media (YouTube, LinkedIn).

Concluding conference and publication of its proceedings (opens in new window)

The conference will be organised as a side event at an established AM event (such as the IIW conference) and with its proceeding published in a high-impact journal.

"""Training of trainers"" courses for WAAM professionals (F)" (opens in new window)

This deliverable consists of the content of a “Training of trainers” course for engineers working with WAAM equipment. The course content will include information on state-of-the-art capabilities developed by Grade2XL (dual robotic deposition, graded structures, special WAAM wires).

Initial communication tools: website, communication toolkit, initial video (opens in new window)

A project website, a visual identity guide, social media tools and a video promoting the project’s ambition.

"""Training of trainers"" courses for WAAM professionals (P)" (opens in new window)

This deliverable consists of the content of a “Training of trainers” course for engineers working with WAAM equipment. The course content will include information on state-of-the-art capabilities developed by Grade2XL (dual robotic deposition, graded structures, special WAAM wires).

Other (1)
Design tool for graded structures with minimum distortions (opens in new window)

This deliverable will consist of a FEM model implemented in a commercially available code, along with guidelines for the transfer of the solution to similar engineering problems.

Publications

Peer reviewed articles (10)
Quantitative sustainability assessment of metal additive manufacturing: A systematic review (opens in new window)

Author(s): Valentina Pusateri, Michael Zwicky Hauschild, Sami Kara, Constantinos Goulas, Stig Irving Olsen
Published in: CIRP Journal of Manufacturing Science and Technology, Issue Volume 49, 2024, 2024, Page(s) 95-110, ISSN 1755-5817
Publisher: Elsevier BV
DOI: 10.1016/j.cirpj.2023.12.005

Fabrication of low thermal expansion Fe–Ni alloys by in-situ alloying using twin-wire arc additive manufacturing (opens in new window)

Author(s): Arjun Sood, Jim Schimmel, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Published in: Materials & Design, Issue 240, 2024, ISSN 0264-1275
Publisher: Elsevier BV
DOI: 10.1016/j.matdes.2024.112837

Directed energy deposition of Invar 36 alloy using cold wire pulsed gas tungsten arc welding: Effect of heat input on the microstructure and functional behaviour (opens in new window)

Author(s): Arjun Sood, Jim Schimmel, Vitoria M. Ferreira, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Published in: Journal of Materials Research and Technology, Issue Volume 25,2023, 2023, Page(s) 6183-6197, ISSN 2238-7854
Publisher: Elsevier Editora Ltda
DOI: 10.1016/j.jmrt.2023.06.280

Functional grading of low alloy steel to 316 L by wire arc additive manufacturing – Microstructural and mechanical characterization of bi-metal interface (opens in new window)

Author(s): J.L. Galán Argumedo, M. Mahmoudiniya, T.E. Reinton, L.A.I. Kestens, M.J.M. Hermans, V.A. Popovich
Published in: Journal of Materials Processing Technology, Issue Volume 325, 2024, 2024, ISSN 0924-0136
Publisher: Elsevier BV
DOI: 10.1016/j.jmatprotec.2024.118305

The use of a measuring arm with a laser scanner for analysis and support of regenerative surfacing processes of forging dies (opens in new window)

Author(s): Marcin Kaszuba; Paweł Widomski; Tomasz Kiełczawa; Zbigniew Gronostajski
Published in: Welding Technology Review, Issue Vol. 92 No. 3, 2020, ISSN 2449-7959
Publisher: Publishing Agency of the Society of Polish Mechanical Engineers and Technicians
DOI: 10.26628/wtr.v92i3.1103

Potential for absolute sustainability of Wire-Arc Additive Manufacturing: A boat propellers case (opens in new window)

Author(s): Valentina Pusateri, Stig Irving Olsen, Michael Z. Hauschil, Sami Kara
Published in: CIRP Annals - Manufacturing Technology, 2023, ISSN 0007-8506
Publisher: Hallwag AG
DOI: 10.1016/j.cirp.2023.04.034

Anomaly Detection in WAAM Deposition of Nickel Alloys—Single-Material and Cross-Material Analysis (opens in new window)

Author(s): Rajesh, Aditya, Wei Ya, and Marcel Hermans.
Published in: Metals, Issue 13, 2023, ISSN 2075-4701
Publisher: MDPI
DOI: 10.3390/met13111820

Study of the effect of defects on fatigue life prediction of additive manufactured Ti-6Al-4V by combined use of micro-computed tomography and fracture-mechanics-based simulation (opens in new window)

Author(s): Shiwei Han, Tien Dung Dinh, Ives De Baere, Matthieu Boone, Iván Josipovic, Wim Van Paepegem
Published in: International Journal of Fatigue, Issue Volume 180, 2024, 2024, ISSN 0142-1123
Publisher: Elsevier BV
DOI: 10.1016/j.ijfatigue.2023.108110

A smooth single-variable-based interpolation function for multi-material topology optimization (opens in new window)

Author(s): Dinh, T. D., Hedayatrasa, S., Bormann, F., Bosman, M., Van Paepegem, W.
Published in: Engineering with Computers, 2024, ISSN 1435-5663
Publisher: SpringerLink
DOI: 10.1007/s00366-024-01945-9

Measurement of Three-Dimensional Concentric and Angular Misalignment in Static and Fatigue Testing of Materials by Stereo-Digital Image Correlation (opens in new window)

Author(s): S. Han; T. D. Dinh; I. De Baere; W. Van Paepegem
Published in: Crossref Experimental Mechanics, Issue 63, 2022, Page(s) 1239-1254, ISSN 1741-2765
Publisher: SpringerLink
DOI: 10.1007/s11340-023-00984-5

Other (50)
Deliverable 7.05: Initial communication toolkit

Author(s): EMC2
Published in: 2024
Publisher: Grade2XL

Mechanical behaviour interface of low-alloy to 316L stainless steel produced through WAAM – Part 1 – quasi-static deformation and fracture toughness

Author(s): TU Delft, in preparation
Published in: 2025
Publisher: Unknown

Deliverable 5.01: List of available guidelines

Author(s): Bureau Veritas
Published in: 2024
Publisher: Grade2XL

Deliverable 7.09: Intermidiate dissemination and exploitation plan

Author(s): EMC2
Published in: 2024
Publisher: Grade2XL

How does Wire-Arc Additive Manufacturing perform from a resource accessibility perspective?

Author(s): DTU, poster presented
Published in: 2023
Publisher: 11th International Conference on Life Cycle Management, 2023

Deliverable 7.1: Initial dissemination and exploitation plan

Author(s): EMC2
Published in: 2024
Publisher: Grade2XL

T.B.C., 1st article for final results WP1, in preparation

Author(s): TU Delft
Published in: 2025
Publisher: Unknown

Wire + Arc Additive Manufacturing of Functionally -graded HSLA and Austenitic Stainless Steel Bi-material Structures.

Author(s): TU Delft, presentation
Published in: 2023
Publisher: TMS 2023

On the relationship between microstructure and elastic constants measured by resonant ultrasonic spectroscopy: from single crystals to additively manufactured polycrystals

Author(s): CEA, presentation
Published in: 2024
Publisher: IIW 2024

T.B.C

Author(s): CEA, in preparation
Published in: 2025
Publisher: AIP Publisher

Grade2XL Graded Wire and Arc Additive Manufacturing

Author(s): TU Delft
Published in: 2022
Publisher: IIW 2022

Inoculation as grain refinement strategy for Wire Arc Manufacturing of Invar36

Author(s): TU Delft, 3rd Master Thesis
Published in: 2024
Publisher: TU Delft

Indentation Plastometry for optimization of WAAM deposit

Author(s): TU Delft, 1st Internship
Published in: 2025
Publisher: TU Delft

Anomaly Detection in WAAM Deposition of Nickel Alloys

Author(s): TU Delft, 2nd master thesis
Published in: 2024
Publisher: TU Delft

Local stress-constrained topology optimization of thermoelastic structures using the augmented Lagrangian approach

Author(s): UGent, in preparation
Published in: 2025
Publisher: Unknown

Sustainability of recycled stainless steel in 3D printed items vs. conventional manufacturing

Author(s): DTU
Published in: 2024
Publisher: Unknown

3D Printing and Surfacing of Inconel 625 through Automated Wire Arc Additive Manufacturing

Author(s): RAMLAB, presentation
Published in: 2024
Publisher: IIW 2024

T.B.C.

Author(s): PWR, in preparation
Published in: 2025
Publisher: Unknown

Resonant ultrasound elastic characterization of Steel Wire Arc Additive Manufacturing samples

Author(s): CEA, in preperation
Published in: 2025
Publisher: Unknown

Wire arc additive manufacturing of Ni-Fe alloy/ductile cast iron bimetallic structure; Phase transformations, microstructure and crystallographic texture

Author(s): UGent, submitted to journal
Published in: 2025
Publisher: Unknown

Fatigue behaviour

Author(s): TU Delft, 7th Master Thesis, in preparation
Published in: 2025
Publisher: TU Delft

Mitigation of ductility dip cracking during WAAM of Invar 36 alloy

Author(s): TU Delft, UTwente, presentation
Published in: 2024
Publisher: IIW 2024

Microstructure and texture development during printing of Fe-Ni alloy on a ductile cast iron substrate by Wire and Arc Additive Manufacturing

Author(s): UGent, extended abstract presented
Published in: 2022
Publisher: Metal Additive Manufacturing Conference - MAMC 2022

Deliverable 7.10: Coaching sessions for SMEs (P)

Author(s): EMC2
Published in: 2024
Publisher: Grade2XL

T.B.C., 1rd article for final results WP1, in preparation

Author(s): UGent
Published in: 2025
Publisher: Unknown

The effect of Cryogenic cooling on the microstructure and mechanical properties of Wire and Arc Additively Manufactured steels

Author(s): RAMLAB and Air Products, presentation
Published in: 2024
Publisher: IIW 2024

Deliverable D6.1 Preliminary LCA and LCC

Author(s): Stig Irving Olsen, Valentina Pusateri
Published in: Grade2XL website, 2024
Publisher: Grade2XL

Repair of Tool Steels by the method GMAW-WAAM

Author(s): TU Delft, 4rd Master Thesis in preparation
Published in: 2025
Publisher: TU Delft

T.B.C., presentation at IIW 2024

Author(s): PWR, presentation
Published in: 2024
Publisher: IIW 2024

Automatic additive repair through using the MaxQ system developed at RAMLAB

Author(s): TU Delft, 2nd Internship
Published in: 2025
Publisher: TU Delft

Reconstruction of smooth shape defects in additive manufactured waveguides by laser-ultrasound.

Author(s): CEA, presentation
Published in: 2024
Publisher: AFPAC 2024

Mech Characterisation

Author(s): TU Delft, 5th Master Thesis, in preparation
Published in: 2025
Publisher: TU Delft

Fatigue and Fracture of Bi-metallic Parts Produced through Wire Arc Additive Manufacturing

Author(s): TU Delft, presentation
Published in: 2024
Publisher: TMS 2024

Deposition of Low Thermal Expansion Invar Alloys Using Wire Arc Additive Manufacturing

Author(s): TU Delft, 3rd Master thesis
Published in: 2024
Publisher: TU Delft

Modeling solidification structures in 3D printed metals created by Wire Arc Additive Manufacturing

Author(s): UGent, 1st Master thesis
Published in: 2024
Publisher: UGent

T.B.C., 2nd article for final results WP1, in preparation

Author(s): TU Delft
Published in: 2025
Publisher: Unknown

Dissipative flows of Au, Cu, and Fe in the technosphere and implications for resource use impact assessment

Author(s): DTU, in preperation
Published in: 2025
Publisher: Unknown

T.B.C. in preparation

Author(s): UGent, in preparation
Published in: 2025
Publisher: Unknown

Mechanical and structural properties of materials produced by WAAM technology dedicated to tool repair and for increasing tool life in forging processes

Author(s): PWR, in preparation
Published in: 2025
Publisher: Unknown

LCA and LCC of wire arc additively manufactured and repaired parts compared to conventional fabrication techniques

Author(s): DTU, paper in proceedings
Published in: 2024
Publisher: 31st CIRP Conference on Life Cycle Engineering (LCE 2024)

Deliverable 7.11: Coaching sessions for SMEs (I-2)

Author(s): EMC2
Published in: 2024
Publisher: Grade2XL

Prospective absolute sustainability of products manufactured with multi-material Wire-arc Additive Manufacturing

Author(s): DTU, in preperation
Published in: 2025
Publisher: Unknown

Grain refinement -inoculants in invar

Author(s): TU Delft, in preparation
Published in: 2025
Publisher: Unknown

Mechanical behaviour interface of low-alloy to 316L stainless steel produced through WAAM – Part 2 - Fatigue crack propagation

Author(s): TU Delft, in preparation
Published in: 2025
Publisher: Unknown

Neural network-based topology optimization of thermoelastic structures

Author(s): UGent, 2nd Master Thesis
Published in: 2024
Publisher: UGent

Multi-material topology optimization of structural components subjected to thermo-mechanical loads

Author(s): UGent, 3rd Master Thesis
Published in: 2024
Publisher: UGent

In-situ synthesis of Invar alloys by dual-wire deposition using WAAM

Author(s): TU Delft, presentation
Published in: 2023
Publisher: TMS 2023

Characterization of effective elastic constants and anisotropy directions for Wire Arc Additive Manufactured steel samples using RUS

Author(s): CEA, presentation at ASA spring meeting 2024 Ottawa
Published in: 2024
Publisher: ASA spring meeting 2024 Ottawa

Potential for absolute sustainability of Wire-Arc Additive Manufacturing: A boat propellers case

Author(s): DTU, oral presentation
Published in: 2023
Publisher: 72nd CIRP General Assembly 2023

Repair WAAM

Author(s): TU Delft, 6th Master Thesis, in preparation
Published in: 2025
Publisher: TU Delft

Conference proceedings (5)
An Absolute Sustainability Approach for Holistic Planning of a Product Fabrication with Additive Manufacturing

Author(s): Valentina Pusateri, Stig Olsen
Published in: SETAC Europe 25th LCA Symposium, 2022, Page(s) Article number 2.05
Publisher: SETAC Europe 25th LCA Symposium

Implementation of Non Destructive Testing and in-line monitoring techniques on extra-large structures printed with WAAM technology (opens in new window)

Author(s): Gardahaut, A., Charau, A., Le Bourdais, F., Stolidi, A., & Sargeeva-Chollet, N.
Published in: e-Journal of Nondestructive Testing, Issue Volume 28(9), 2023
Publisher: LES JOURNÉES COFREND/ COFREND DAYS
DOI: 10.58286/28477

The Effect of Cryogenic Cooling on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Steels

Author(s): Constantinos Goulas, Maximus Akuh, Vignesh Venkata Subramanian, Remco Rook, José Galán Argumedo, Theodoros Michelis, Marco Ameye, Wei Ya, Ian Gibson, Marcel Hermans
Published in: TMS 2023 152nd Annual Meeting and Exhibition, 2023
Publisher: TMS 2023

An efficient multi-material topology optimization method for thermoelastic structures

Author(s): Tien Dung Dinh, Saeid Hedayatrasa, Franz Bormann, Marko Bosman and Wim Van Paepegem
Published in: WCSMO-15, the 15th World Congress of Structural and Multidisciplinary Optimization, Abstracts, 2023
Publisher: WCSMO-15 : the 15th World Congress of Structural and Multidisciplinary Optimization

Monitoring en ligne par fluorescence X des procédés de fabrication additive métallique (opens in new window)

Author(s): Stolidi, A., Touron, A., Toulemonde, L., Gardahaut, A., & Garandet, J.
Published in: e-Journal of Nondestructive Testing, Issue Volume 28(9), 2023
Publisher: LES JOURNÉES COFREND/ COFREND DAYS
DOI: 10.58286/28476

Book chapters (1)
Technical Challenges and Future Environmentally Sustainable Applications for Multi-Material Additive Manufacturing for Metals (opens in new window)

Author(s): Valentina Pusateri, Constantinos Goulas and Stig Irving Olsen
Published in: Advances in 3D Printing, 2023, ISBN 978-1-80355-845-5
Publisher: IntechOpen
DOI: 10.5772/intechopen.109788

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Last update: 18 July 2025

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Permalink: https://cordis.europa.eu/project/id/862017/results

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