WP1 Life cycle analysis and impact assessment (LCA) covered the environmental impacts acc. to ISO 14040 and 14044 standards. The LCA method RECIPE was applied for 13 impact categories in deliverable D1.3. Health & Safety (HSE) activities treated the nanoparticles emission monitoring at several partners sites.
WP2 Advanced AM Materials for multifunctional performance (MATERIALS) treated several novel AM materials, incl. Cu-coated Mo & W particles and AlTiC, AlTiB2, and FeCrAl powders, novel Al alloys and optical fibre with Ni and/or Cu coatings. Multi-material designs were investigated for steel, INVAR , Cu and Al alloys as well as ceramics.
WP3 Advanced AM-Equipment for in-situ -Multi-Functionalities by Multi-Materials (EQUIPMENT) focused systems for wire and powder, applying electric arc, laser or plasma energy. Deposition of powders with conductive & insulating properties was improved. Software enabling the multi-material and multi-functionality of part manufacturing was adopted for a faster and more reliable processing.
WP4 Evaluation of Multi-Materials and Multi-Functionalities (EVALUATION) covered the characterization of bulk microstructures and interfaces, regarding mechanical and thermal properties. Visual, ultrasonic and x-ray radiography testing incl. Synchrotron micro-tomography analysis provided detailed insight into samples and real size demonstrators regarding porosity, lack of fusion, multi-material interfaces and the integrity of embedded optical fibres and electrical conductors.
WP5 Use Case Demonstrations (USE CASES) successfully achieved the design and manufacturing of all 7 demonstrators:
DEMO1 – Actuator Housing (for space application, thumb-sized, out of standard stainless steel plus integrated standard copper, doubling the heat transfer rates)
DEMO2 – Bulkhead Panel (aviation related hybrid part out of standard aerospace & novel aluminium grade alloy in combination with coated optical fibres adding an embedded structural health monitoring (SHM) capability. The metal coating of OFs and equipment for OF integration by WAAM were subject matters of 2 patent applications. An eco-efficiency improvement of >60% was achieved.
DEMO3 – See through A-pillar (WAAM of standard steel grade in combination with standard CANbus cables integrated by APPD zinc coating) features a revolutionary design solving the vehicle safety issue of blind spots.
DEMO4 – Motorbike Handlebar (Novel aluminium alloy combined with Al2O3 insulation layers and copper conductors substituting electrical cables (for lights, indicators or starter) in a WAAM aluminium structure besides integrated hydraulic channels.)
DEMO5 – Die insert (Standard tool steel combined with sintered, nanotechnology-based DiaCool sintered feedstock) for aluminium die casting.
DEMO6 – Mould for CFRP Parts (Invar plus copper) designed for electr. heated, out-of-autoclave manufacturing of carbon-fibre reinforced polymers) indicating a potential to raise an eco-efficiency improvement >25%.
DEMO7 – Hydrogen Gas Temperature Control unit (Novel aluminium alloy coated with ceramic insulation layers , integration of OFs in spiral manner) for increased dynamics in H2 preconditioning.
Lessons learnt across all demonstrators were published as a report (deliverable).
WP6 Dissemination, Exploitation & Communication (DEC) focused on dissemination via papers, presentations etc., conducted 4 public events (2 SpeedTech Forums , 1 MULTI-FUN Talks, 1 training session) and participated in working group on standardisation.
