Application of Functionally Graded Materials to Extra-Large Structures

Informazioni relative al progetto

Grade2XL

ID dell’accordo di sovvenzione: 862017

DOI

10.3030/862017

Progetto chiuso

Data della firma CE 8 Aprile 2020

Data di avvio 1 Marzo 2020

Data di completamento 31 Agosto 2024

Finanziato da

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

Costo totale

€ 9 752 666,25

Contributo UE

€ 7 910 280,00

Coordinato da

STICHTING MATERIALS INNOVATION INSTITUTE (M2I)
Netherlands

CORDIS fornisce collegamenti ai risultati finali pubblici e alle pubblicazioni dei progetti ORIZZONTE.

I link ai risultati e alle pubblicazioni dei progetti del 7° PQ, così come i link ad alcuni tipi di risultati specifici come dataset e software, sono recuperati dinamicamente da .OpenAIRE .

Risultati finali

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.

Pubblicazioni

Peer reviewed articles (10)

Quantitative sustainability assessment of metal additive manufacturing: A systematic review

Autori: Valentina Pusateri, Michael Zwicky Hauschild, Sami Kara, Constantinos Goulas, Stig Irving Olsen
Pubblicato in: CIRP Journal of Manufacturing Science and Technology, Numero Volume 49, 2024, 2024, Pagina/e 95-110, ISSN 1755-5817
Editore: 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

Autori: Arjun Sood, Jim Schimmel, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Pubblicato in: Materials & Design, Numero 240, 2024, ISSN 0264-1275
Editore: 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

Autori: Arjun Sood, Jim Schimmel, Vitoria M. Ferreira, Marko Bosman, Constantinos Goulas, Vera Popovich, Marcel J.M. Hermans
Pubblicato in: Journal of Materials Research and Technology, Numero Volume 25,2023, 2023, Pagina/e 6183-6197, ISSN 2238-7854
Editore: 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

Autori: J.L. Galán Argumedo, M. Mahmoudiniya, T.E. Reinton, L.A.I. Kestens, M.J.M. Hermans, V.A. Popovich
Pubblicato in: Journal of Materials Processing Technology, Numero Volume 325, 2024, 2024, ISSN 0924-0136
Editore: 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

Autori: Marcin Kaszuba; Paweł Widomski; Tomasz Kiełczawa; Zbigniew Gronostajski
Pubblicato in: Welding Technology Review, Numero Vol. 92 No. 3, 2020, ISSN 2449-7959
Editore: 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

Autori: Valentina Pusateri, Stig Irving Olsen, Michael Z. Hauschil, Sami Kara
Pubblicato in: CIRP Annals - Manufacturing Technology, 2023, ISSN 0007-8506
Editore: Hallwag AG
DOI: 10.1016/j.cirp.2023.04.034

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

Autori: Rajesh, Aditya, Wei Ya, and Marcel Hermans.
Pubblicato in: Metals, Numero 13, 2023, ISSN 2075-4701
Editore: 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

Autori: Shiwei Han, Tien Dung Dinh, Ives De Baere, Matthieu Boone, Iván Josipovic, Wim Van Paepegem
Pubblicato in: International Journal of Fatigue, Numero Volume 180, 2024, 2024, ISSN 0142-1123
Editore: Elsevier BV
DOI: 10.1016/j.ijfatigue.2023.108110

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

Autori: Dinh, T. D., Hedayatrasa, S., Bormann, F., Bosman, M., Van Paepegem, W.
Pubblicato in: Engineering with Computers, 2024, ISSN 1435-5663
Editore: 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

Autori: S. Han; T. D. Dinh; I. De Baere; W. Van Paepegem
Pubblicato in: Crossref Experimental Mechanics, Numero 63, 2022, Pagina/e 1239-1254, ISSN 1741-2765
Editore: SpringerLink
DOI: 10.1007/s11340-023-00984-5

Other (50)

Deliverable 7.05: Initial communication toolkit

Autori: EMC2
Pubblicato in: 2024
Editore: Grade2XL

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

Autori: TU Delft, in preparation
Pubblicato in: 2025
Editore: Unknown

Deliverable 5.01: List of available guidelines

Autori: Bureau Veritas
Pubblicato in: 2024
Editore: Grade2XL

Deliverable 7.09: Intermidiate dissemination and exploitation plan

Autori: EMC2
Pubblicato in: 2024
Editore: Grade2XL

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

Autori: DTU, poster presented
Pubblicato in: 2023
Editore: 11th International Conference on Life Cycle Management, 2023

Deliverable 7.1: Initial dissemination and exploitation plan

Autori: EMC2
Pubblicato in: 2024
Editore: Grade2XL

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

Autori: TU Delft
Pubblicato in: 2025
Editore: Unknown

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

Autori: TU Delft, presentation
Pubblicato in: 2023
Editore: TMS 2023

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

Autori: CEA, presentation
Pubblicato in: 2024
Editore: IIW 2024

T.B.C

Autori: CEA, in preparation
Pubblicato in: 2025
Editore: AIP Publisher

Grade2XL Graded Wire and Arc Additive Manufacturing

Autori: TU Delft
Pubblicato in: 2022
Editore: IIW 2022

Inoculation as grain refinement strategy for Wire Arc Manufacturing of Invar36

Autori: TU Delft, 3rd Master Thesis
Pubblicato in: 2024
Editore: TU Delft

Indentation Plastometry for optimization of WAAM deposit

Autori: TU Delft, 1st Internship
Pubblicato in: 2025
Editore: TU Delft

Anomaly Detection in WAAM Deposition of Nickel Alloys

Autori: TU Delft, 2nd master thesis
Pubblicato in: 2024
Editore: TU Delft

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

Autori: UGent, in preparation
Pubblicato in: 2025
Editore: Unknown

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

Autori: DTU
Pubblicato in: 2024
Editore: Unknown

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

Autori: RAMLAB, presentation
Pubblicato in: 2024
Editore: IIW 2024

T.B.C.

Autori: PWR, in preparation
Pubblicato in: 2025
Editore: Unknown

Resonant ultrasound elastic characterization of Steel Wire Arc Additive Manufacturing samples

Autori: CEA, in preperation
Pubblicato in: 2025
Editore: Unknown

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

Autori: UGent, submitted to journal
Pubblicato in: 2025
Editore: Unknown

Fatigue behaviour

Autori: TU Delft, 7th Master Thesis, in preparation
Pubblicato in: 2025
Editore: TU Delft

Mitigation of ductility dip cracking during WAAM of Invar 36 alloy

Autori: TU Delft, UTwente, presentation
Pubblicato in: 2024
Editore: IIW 2024

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

Autori: UGent, extended abstract presented
Pubblicato in: 2022
Editore: Metal Additive Manufacturing Conference - MAMC 2022

Deliverable 7.10: Coaching sessions for SMEs (P)

Autori: EMC2
Pubblicato in: 2024
Editore: Grade2XL

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

Autori: UGent
Pubblicato in: 2025
Editore: Unknown

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

Autori: RAMLAB and Air Products, presentation
Pubblicato in: 2024
Editore: IIW 2024

Deliverable D6.1 Preliminary LCA and LCC

Autori: Stig Irving Olsen, Valentina Pusateri
Pubblicato in: Grade2XL website, 2024
Editore: Grade2XL

Repair of Tool Steels by the method GMAW-WAAM

Autori: TU Delft, 4rd Master Thesis in preparation
Pubblicato in: 2025
Editore: TU Delft

T.B.C., presentation at IIW 2024

Autori: PWR, presentation
Pubblicato in: 2024
Editore: IIW 2024

Automatic additive repair through using the MaxQ system developed at RAMLAB

Autori: TU Delft, 2nd Internship
Pubblicato in: 2025
Editore: TU Delft

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

Autori: CEA, presentation
Pubblicato in: 2024
Editore: AFPAC 2024

Mech Characterisation

Autori: TU Delft, 5th Master Thesis, in preparation
Pubblicato in: 2025
Editore: TU Delft

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

Autori: TU Delft, presentation
Pubblicato in: 2024
Editore: TMS 2024

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

Autori: TU Delft, 3rd Master thesis
Pubblicato in: 2024
Editore: TU Delft

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

Autori: UGent, 1st Master thesis
Pubblicato in: 2024
Editore: UGent

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

Autori: TU Delft
Pubblicato in: 2025
Editore: Unknown

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

Autori: DTU, in preperation
Pubblicato in: 2025
Editore: Unknown

T.B.C. in preparation

Autori: UGent, in preparation
Pubblicato in: 2025
Editore: Unknown

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

Autori: PWR, in preparation
Pubblicato in: 2025
Editore: Unknown

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

Autori: DTU, paper in proceedings
Pubblicato in: 2024
Editore: 31st CIRP Conference on Life Cycle Engineering (LCE 2024)

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

Autori: EMC2
Pubblicato in: 2024
Editore: Grade2XL

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

Autori: DTU, in preperation
Pubblicato in: 2025
Editore: Unknown

Grain refinement -inoculants in invar

Autori: TU Delft, in preparation
Pubblicato in: 2025
Editore: Unknown

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

Autori: TU Delft, in preparation
Pubblicato in: 2025
Editore: Unknown

Neural network-based topology optimization of thermoelastic structures

Autori: UGent, 2nd Master Thesis
Pubblicato in: 2024
Editore: UGent

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

Autori: UGent, 3rd Master Thesis
Pubblicato in: 2024
Editore: UGent

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

Autori: TU Delft, presentation
Pubblicato in: 2023
Editore: TMS 2023

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

Autori: CEA, presentation at ASA spring meeting 2024 Ottawa
Pubblicato in: 2024
Editore: ASA spring meeting 2024 Ottawa

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

Autori: DTU, oral presentation
Pubblicato in: 2023
Editore: 72nd CIRP General Assembly 2023

Repair WAAM

Autori: TU Delft, 6th Master Thesis, in preparation
Pubblicato in: 2025
Editore: TU Delft

Conference proceedings (5)

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

Autori: Valentina Pusateri, Stig Olsen
Pubblicato in: SETAC Europe 25th LCA Symposium, 2022, Pagina/e Article number 2.05
Editore: SETAC Europe 25th LCA Symposium

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

Autori: Gardahaut, A., Charau, A., Le Bourdais, F., Stolidi, A., & Sargeeva-Chollet, N.
Pubblicato in: e-Journal of Nondestructive Testing, Numero Volume 28(9), 2023
Editore: 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

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

An efficient multi-material topology optimization method for thermoelastic structures

Autori: Tien Dung Dinh, Saeid Hedayatrasa, Franz Bormann, Marko Bosman and Wim Van Paepegem
Pubblicato in: WCSMO-15, the 15th World Congress of Structural and Multidisciplinary Optimization, Abstracts, 2023
Editore: WCSMO-15 : the 15th World Congress of Structural and Multidisciplinary Optimization

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

Autori: Stolidi, A., Touron, A., Toulemonde, L., Gardahaut, A., & Garandet, J.
Pubblicato in: e-Journal of Nondestructive Testing, Numero Volume 28(9), 2023
Editore: 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

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