Periodic Reporting for period 2 - MULTI-FUN (Enabling MULTI-FUNctional performance through multi-material additive manufacturing) Reporting period: 2021-09-01 to 2022-08-31 Summary of the context and overall objectives of the project The project focus on developing advanced materials and equipment for AM of multi-material partsNew material combinations will give a significant performance and efficiency boost to MAM products through fully integrated multi-functionalities based on novel active materials, enabling multi-material design without size limitationsNew functionalities include embedded electrical conductivity, fibre-optic sensing features & innovative heat management concepts (inc. app. of nanotechnologies)OBJ1 DEVELOPMENT OF NEW MATERIALS CUSTOMIZED FOR AMUse of nano-tech. to maximize thermal conductivity, minimize electrical conductivity &/or improve wear resistance of metals – always optimizing its compatibility to the metal bulkRecent developments of Al alloys and low alloyed steel grades will be further developed for WAAM Coating of optical fibres (OF) will be developed to maintain sensing capabilitiesIn-situ alloying will provide further advanced materials solutions with high flexibility in compositions and adjusted material propertiesOBJ2 DEVELOPMENT OF AM EQUIPMENT AND AM SOFTWARE Developments on AM hardware are driven by the need to combine different materials in distinguishable manner within a structureIt will produce requested material compositions during the layer build up: in-situ alloying applies wire+wire or wire+powder feedstock by WAAM and APPDWire+OF to allow sensing capabilities: APPD will generate electrical conductive layers in between insulating layers in metal bodies & OF and Cu lines to transfer dataOBJ3 MANUFACTURING AND EVALUATION OF DEMONSTRATORSNew materials and technologies will be applied in 10 different combinations in 7 demonstrators, belonging to 3 use cases (structural parts, moulds, test equipment)Address of 4 different markets (automotive, aviation, space and production industry) taking advantage of the high built-up rate of WAAM and specialized AM processes for the integration of active materialsOBJ4 SUPERVISING THE SIGNIFICANT REDUCTION OF ENVIRONMENTAL AND ECONOMIC IMPACT BY LCAAM materials, hardware, process strategy and demonstrator design and manufacturing will be continuously supervised through feedback loops improvedLCA, LCC, safety and Eco-efficiency will ensure increase in efficiency, quality and reliability as well as the reduction of resources and cost Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far WP1 Safety & environment analysis on the requirements for the design of materials, processes and demos; Workshop on LCA methodology and LCI, and interaction with partners to support data collection; Establishment of methods to estimate H&E risk of production by-products and pilot experiments on cytotoxicity and antimicrobial activity, using a number of nanoparticles and nanowiresWP2 Development of: Technical specifications of requirements for multi-materials & -functionalities; Cu coating of Mo and DiaCool particles with homogeneous 100 and 300nm thickness via PVD and Al-TiC nanocomposites by mixing micron Al particles with 50nm TiC nanoparticles for wire extrusion; New high strength aluminium wire (Al-Zn-Mg-Cu) with impressive mechanical properties (Rp0.2 > 390 MPa, Rm > 470, MPa, A> 5%); in-situ compositions of Invar 36, Al-Cu and Al-Mg wires and Cu MMCs. Production of OF with Cu, Au & Ni metallic coatings and successfully embedment by WAAM in Al-based componentsWP3 Development of 10 different systems using laser & arc deposition; and their respective deposit of several different metals, from Invar to stainless steel, several Al alloys, Cu conductive tracks etcEmbedding of OF into Al WAAM parts was successfully demonstrated and the software developed has been expanded and tested by 2 partners and can drive multi-process systemsWP4 Performed a comprehensive characterisation of nano-treated wires for demo 2; Design of cooling channels and multi-material die inserts for demo 5; WAAM walls manufactured for mechanical characterization and non-destructive testing & Identification of the particular demonstrator-oriented testing routines.WP5 Development of: time plan regarding technology and staff availability for several demos; Strong interrelation with manufacturing partners and developed technology established; and Initial design with emphasis on functional integration for the majority of demonstrators in discussionWP6 Set-up of the DEC strategy and plan and its implementation in what concerns building community & networking activities and development of: communication tools & measures and standard press material; plan for knowledge transfer activities; draft plan for SpeedTech forums and MULTI-FUN talks and plan and implementation of standardisation activities Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far) MULTI-FUN will overcome PBF-LB process restrictions by:Provide a significant performance & efficiency gain in MAM products by fully integrated multi-functionalities based on novel active materials Enable multi-material design in geometrically complex 3D metal parts without size limitation by innovative, cost-effective AM technologiesResults 1 ADVANCED METALLIC MATERIALS2 NOVEL AM EQUIPMENT3 MULTI-MATERIAL DESIGN-KNOWLEDGE4 STANDARDISATION KNOWLEDGEImpactImprovement of the efficiency, quality and reliability of the product exploiting nanotechnology for optimising material parameters, to result in: - Heat sink material with highest conductivity- Enhanced local heat transfer efficiency - Improvement of thermal regulation dynamics, production rates & properties of parts produced - Increased mould lifetime- Multi-sectorial approach with high level of transferability to other markets - Enabling radical new design in load carrying vehicle structures, generating frontrunner position due to gains in safety, reliability and comfort- Digital integration of multi-functional “wired” parts into condition-based monitoring and digital twin process control leading to reduced downtimes, less scrap & lower energy consumption- Paving the way for SHM for metal parts into aviation industryBetter use of raw materials and resources with reduced environmental impact and lower cost enabling multi-material parts by exploiting WAAM in cooperation with other cost-effective processes to realize multi-functionalities by added active materials resulting in:- Significantly reducing production waste - Integrated functionalities leading to enhanced lifetime - Highly integrative design leading to reductions in no. of single parts, leading to the reduction in causes of failures and maintenance needs- Environmental impact supervised by LCA concerning cradle-to-grave energy and raw material consumption- Reduction of production waste- Implementation of multi-material forming tools in conventional forming processes for energy reduction & enhanced productivity- Transfer of multi-material opportunities to other forming processes (hot stamping, composite curing, sintering)- Opening up radical design concepts for moulds and parts in context of predictive maintenance- Further improvement in durability and lifespan of machinery by integrated condition sensors New opportunities & business for SMEs across EU- Offers along the entire value chain will be developed and distributed by beneficiaries- Inclusion of insights into curricula of 5 EU Unis - Set up and delivery of training for SMEs on AM- Positioning of SMEs as frontrunner for AM-materials, equipment, quality, as international quality leader- Setting up training activities for SMEs to build and enhance AM capacities throughout EU on the long term Related documents MULTI-FUN Demonstrators.JPG
