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CORDIS

Application of Functionally Graded Materials to Extra-Large Structures

Project description

A 3D-printing method for high-performance 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. The EU-funded 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.

Objective

Large engineering structures like turbines, bridges or industrial machinery are still manufactured by traditional processes such as forging, casting or by machining from solid blocks. These processes do not allow local control of material properties to achieve a specific function like anti-corrosion or hardness. To meet the functional specifications, engineers must operate within a limited range of design options, with high “buy-to-fly” ratios and long lead times.

Unlike any other metal AM technology, wire arc additive manufacturing (WAAM) produces fully dense metallic structures with no porosity. WAAM is also unbeatable in terms of production times, making it uniquely suited for large and functionally demanding engineering structures.

In Grade2XL, we will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large scale structures. The high printing rate of WAAM, combined with the ability to control material properties down to the nanoscale, will allow us to build strong and durable engineering structures. Grade2XL will deliver multi-material products of superior quality and performance, cut lead times by up to 96% and enable massive cost savings for the maritime and energy industry, as well as for industrial machinery. These outputs will rapidly roll out to other sectors with similar key performance indicators and become an attractive investment opportunity for SMEs. This project will strengthen Europe’s capacity to drive manufacturing innovation globally and withstand growing competition from Asia.

Call for proposal

H2020-NMBP-TR-IND-2018-2020

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Sub call

H2020-NMBP-TR-IND-2019

Coordinator

STICHTING MATERIALS INNOVATION INSTITUTE (M2I)
Net EU contribution
€ 457 375,00
Address
VAN DER BURGHWEG 1
2628 CS Delft
Netherlands

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Region
West-Nederland Zuid-Holland Delft en Westland
Activity type
Research Organisations
Links
Total cost
€ 457 375,00

Participants (21)