Application of Functionally Graded Materials to Extra-Large Structures

Informations projet

Grade2XL

N° de convention de subvention: 862017

DOI

10.3030/862017

Projet clôturé

Date de signature de la CE 8 Avril 2020

Date de début 1 Mars 2020

Date de fin 31 Août 2024

Financé au titre de

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced materials

Coût total

€ 9 752 666,25

Contribution de l’UE

€ 7 910 280,00

Coordonné par

STICHTING MATERIALS INNOVATION INSTITUTE (M2I)
Netherlands

CORDIS fournit des liens vers les livrables publics et les publications des projets HORIZON.

Les liens vers les livrables et les publications des projets du 7e PC, ainsi que les liens vers certains types de résultats spécifiques tels que les jeux de données et les logiciels, sont récupérés dynamiquement sur OpenAIRE .

Livrables

Documents, reports (15)

Initial dissemination and exploitation plan

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

Comparative LCA and LCC of the developed technology

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"

Document describing best practices for WAAM manufacturing.

Coaching sessions for SMEs (I-2)

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)

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

Final dissemination and exploitation plan

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

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

Preliminary LCA and LCC

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)

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

Qualification roadmaps

Document describing the qualification steps for the application cases.

Comparative LCA and LCC of the developed technology (F)

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)

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

Public report on WAAM demonstrators

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

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

Public database on material properties and processing parameters

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

Websites, patent fillings, videos etc. (5)

Final communication material

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

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)"

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

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)"

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

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

Auteurs: Valentina Pusateri, Michael Zwicky Hauschild, Sami Kara, Constantinos Goulas, Stig Irving Olsen
Publié dans: CIRP Journal of Manufacturing Science and Technology, Numéro Volume 49, 2024, 2024, Page(s) 95-110, ISSN 1755-5817
Éditeur: 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

Auteurs: Arjun Sood, Jim Schimmel, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Publié dans: Materials & Design, Numéro 240, 2024, ISSN 0264-1275
Éditeur: 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

Auteurs: Arjun Sood, Jim Schimmel, Vitoria M. Ferreira, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Publié dans: Journal of Materials Research and Technology, Numéro Volume 25,2023, 2023, Page(s) 6183-6197, ISSN 2238-7854
Éditeur: 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

Auteurs: J.L. Galán Argumedo, M. Mahmoudiniya, T.E. Reinton, L.A.I. Kestens, M.J.M. Hermans, V.A. Popovich
Publié dans: Journal of Materials Processing Technology, Numéro Volume 325, 2024, 2024, ISSN 0924-0136
Éditeur: 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

Auteurs: Marcin Kaszuba; Paweł Widomski; Tomasz Kiełczawa; Zbigniew Gronostajski
Publié dans: Welding Technology Review, Numéro Vol. 92 No. 3, 2020, ISSN 2449-7959
Éditeur: 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

Auteurs: Valentina Pusateri, Stig Irving Olsen, Michael Z. Hauschil, Sami Kara
Publié dans: CIRP Annals - Manufacturing Technology, 2023, ISSN 0007-8506
Éditeur: Hallwag AG
DOI: 10.1016/j.cirp.2023.04.034

Anomaly Detection in WAAM Deposition of Nickel Alloys—Single-Material and Cross-Material Analysis

Auteurs: Rajesh, Aditya, Wei Ya, and Marcel Hermans.
Publié dans: Metals, Numéro 13, 2023, ISSN 2075-4701
Éditeur: 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

Auteurs: Shiwei Han, Tien Dung Dinh, Ives De Baere, Matthieu Boone, Iván Josipovic, Wim Van Paepegem
Publié dans: International Journal of Fatigue, Numéro Volume 180, 2024, 2024, ISSN 0142-1123
Éditeur: Elsevier BV
DOI: 10.1016/j.ijfatigue.2023.108110

A smooth single-variable-based interpolation function for multi-material topology optimization

Auteurs: Dinh, T. D., Hedayatrasa, S., Bormann, F., Bosman, M., Van Paepegem, W.
Publié dans: Engineering with Computers, 2024, ISSN 1435-5663
Éditeur: 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

Auteurs: S. Han; T. D. Dinh; I. De Baere; W. Van Paepegem
Publié dans: Crossref Experimental Mechanics, Numéro 63, 2022, Page(s) 1239-1254, ISSN 1741-2765
Éditeur: SpringerLink
DOI: 10.1007/s11340-023-00984-5

Other (50)

Deliverable 7.05: Initial communication toolkit

Auteurs: EMC2
Publié dans: 2024
Éditeur: Grade2XL

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

Auteurs: TU Delft, in preparation
Publié dans: 2025
Éditeur: Unknown

Deliverable 5.01: List of available guidelines

Auteurs: Bureau Veritas
Publié dans: 2024
Éditeur: Grade2XL

Deliverable 7.09: Intermidiate dissemination and exploitation plan

Auteurs: EMC2
Publié dans: 2024
Éditeur: Grade2XL

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

Auteurs: DTU, poster presented
Publié dans: 2023
Éditeur: 11th International Conference on Life Cycle Management, 2023

Deliverable 7.1: Initial dissemination and exploitation plan

Auteurs: EMC2
Publié dans: 2024
Éditeur: Grade2XL

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

Auteurs: TU Delft
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: TU Delft, presentation
Publié dans: 2023
Éditeur: TMS 2023

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

Auteurs: CEA, presentation
Publié dans: 2024
Éditeur: IIW 2024

T.B.C

Auteurs: CEA, in preparation
Publié dans: 2025
Éditeur: AIP Publisher

Grade2XL Graded Wire and Arc Additive Manufacturing

Auteurs: TU Delft
Publié dans: 2022
Éditeur: IIW 2022

Inoculation as grain refinement strategy for Wire Arc Manufacturing of Invar36

Auteurs: TU Delft, 3rd Master Thesis
Publié dans: 2024
Éditeur: TU Delft

Indentation Plastometry for optimization of WAAM deposit

Auteurs: TU Delft, 1st Internship
Publié dans: 2025
Éditeur: TU Delft

Anomaly Detection in WAAM Deposition of Nickel Alloys

Auteurs: TU Delft, 2nd master thesis
Publié dans: 2024
Éditeur: TU Delft

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

Auteurs: UGent, in preparation
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: DTU
Publié dans: 2024
Éditeur: Unknown

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

Auteurs: RAMLAB, presentation
Publié dans: 2024
Éditeur: IIW 2024

T.B.C.

Auteurs: PWR, in preparation
Publié dans: 2025
Éditeur: Unknown

Resonant ultrasound elastic characterization of Steel Wire Arc Additive Manufacturing samples

Auteurs: CEA, in preperation
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: UGent, submitted to journal
Publié dans: 2025
Éditeur: Unknown

Fatigue behaviour

Auteurs: TU Delft, 7th Master Thesis, in preparation
Publié dans: 2025
Éditeur: TU Delft

Mitigation of ductility dip cracking during WAAM of Invar 36 alloy

Auteurs: TU Delft, UTwente, presentation
Publié dans: 2024
Éditeur: IIW 2024

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

Auteurs: UGent, extended abstract presented
Publié dans: 2022
Éditeur: Metal Additive Manufacturing Conference - MAMC 2022

Deliverable 7.10: Coaching sessions for SMEs (P)

Auteurs: EMC2
Publié dans: 2024
Éditeur: Grade2XL

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

Auteurs: UGent
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: RAMLAB and Air Products, presentation
Publié dans: 2024
Éditeur: IIW 2024

Deliverable D6.1 Preliminary LCA and LCC

Auteurs: Stig Irving Olsen, Valentina Pusateri
Publié dans: Grade2XL website, 2024
Éditeur: Grade2XL

Repair of Tool Steels by the method GMAW-WAAM

Auteurs: TU Delft, 4rd Master Thesis in preparation
Publié dans: 2025
Éditeur: TU Delft

T.B.C., presentation at IIW 2024

Auteurs: PWR, presentation
Publié dans: 2024
Éditeur: IIW 2024

Automatic additive repair through using the MaxQ system developed at RAMLAB

Auteurs: TU Delft, 2nd Internship
Publié dans: 2025
Éditeur: TU Delft

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

Auteurs: CEA, presentation
Publié dans: 2024
Éditeur: AFPAC 2024

Mech Characterisation

Auteurs: TU Delft, 5th Master Thesis, in preparation
Publié dans: 2025
Éditeur: TU Delft

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

Auteurs: TU Delft, presentation
Publié dans: 2024
Éditeur: TMS 2024

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

Auteurs: TU Delft, 3rd Master thesis
Publié dans: 2024
Éditeur: TU Delft

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

Auteurs: UGent, 1st Master thesis
Publié dans: 2024
Éditeur: UGent

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

Auteurs: TU Delft
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: DTU, in preperation
Publié dans: 2025
Éditeur: Unknown

T.B.C. in preparation

Auteurs: UGent, in preparation
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: PWR, in preparation
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: DTU, paper in proceedings
Publié dans: 2024
Éditeur: 31st CIRP Conference on Life Cycle Engineering (LCE 2024)

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

Auteurs: EMC2
Publié dans: 2024
Éditeur: Grade2XL

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

Auteurs: DTU, in preperation
Publié dans: 2025
Éditeur: Unknown

Grain refinement -inoculants in invar

Auteurs: TU Delft, in preparation
Publié dans: 2025
Éditeur: Unknown

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

Auteurs: TU Delft, in preparation
Publié dans: 2025
Éditeur: Unknown

Neural network-based topology optimization of thermoelastic structures

Auteurs: UGent, 2nd Master Thesis
Publié dans: 2024
Éditeur: UGent

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

Auteurs: UGent, 3rd Master Thesis
Publié dans: 2024
Éditeur: UGent

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

Auteurs: TU Delft, presentation
Publié dans: 2023
Éditeur: TMS 2023

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

Auteurs: CEA, presentation at ASA spring meeting 2024 Ottawa
Publié dans: 2024
Éditeur: ASA spring meeting 2024 Ottawa

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

Auteurs: DTU, oral presentation
Publié dans: 2023
Éditeur: 72nd CIRP General Assembly 2023

Repair WAAM

Auteurs: TU Delft, 6th Master Thesis, in preparation
Publié dans: 2025
Éditeur: TU Delft

Conference proceedings (5)

An Absolute Sustainability Approach for Holistic Planning of a Product Fabrication with Additive Manufacturing

Auteurs: Valentina Pusateri, Stig Olsen
Publié dans: SETAC Europe 25th LCA Symposium, 2022, Page(s) Article number 2.05
Éditeur: SETAC Europe 25th LCA Symposium

Implementation of Non Destructive Testing and in-line monitoring techniques on extra-large structures printed with WAAM technology

Auteurs: Gardahaut, A., Charau, A., Le Bourdais, F., Stolidi, A., & Sargeeva-Chollet, N.
Publié dans: e-Journal of Nondestructive Testing, Numéro Volume 28(9), 2023
Éditeur: 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

Auteurs: Constantinos Goulas, Maximus Akuh, Vignesh Venkata Subramanian, Remco Rook, José Galán Argumedo, Theodoros Michelis, Marco Ameye, Wei Ya, Ian Gibson, Marcel Hermans
Publié dans: TMS 2023 152nd Annual Meeting and Exhibition, 2023
Éditeur: TMS 2023

An efficient multi-material topology optimization method for thermoelastic structures

Auteurs: Tien Dung Dinh, Saeid Hedayatrasa, Franz Bormann, Marko Bosman and Wim Van Paepegem
Publié dans: WCSMO-15, the 15th World Congress of Structural and Multidisciplinary Optimization, Abstracts, 2023
Éditeur: WCSMO-15 : the 15th World Congress of Structural and Multidisciplinary Optimization

Monitoring en ligne par fluorescence X des procédés de fabrication additive métallique

Auteurs: Stolidi, A., Touron, A., Toulemonde, L., Gardahaut, A., & Garandet, J.
Publié dans: e-Journal of Nondestructive Testing, Numéro Volume 28(9), 2023
Éditeur: 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

Auteurs: Valentina Pusateri, Constantinos Goulas and Stig Irving Olsen
Publié dans: Advances in 3D Printing, 2023, ISBN 978-1-80355-845-5
Éditeur: IntechOpen
DOI: 10.5772/intechopen.109788