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Innovative inspection techniques for laser powder deposition quality control

Objective

"Laser Powder Deposition is a recently developed technology for manufacture of small intricate metal parts such as those
used in aerospace and automobile engines. This technology has significant potential advantages over conventional
casting methods in that small parts with internal features can be built, enabling special processes and light structures to be
constructed.
The powder deposition process works by melting a layer of powder in a pattern determined by the path of a laser. The layers
are either 500 μm or 20-50 μm thick depending on the process used.
To take full advantage of the intricacy of form enabled by these additive technology approaches in these applications
commensurate non-destructive inspection capability is needed which can support the cycle times needed in Rapid Agile
manufacture of high performance, high loading efficiency structures. This requires an inspection process capable of handling
the complex evolving forms, in cycle with a processing environment with a feature resolution on a scale relevant to the
component structural elements. This project aims to address this problem and provide non-destructive testing techniques with
known capabilities for the process.
Objectives:
• To provide inspection methods for the laser powder deposition process with known capability.
• To manufacture a prototype laser powder deposition manufacturing system with known inspection capabilities and to
demonstrate these capabilities.
Candidate inspection technologies have been identified that have potential to provide the inspection capability. Note that
these will probably need to be robotically deployed and remotely operated within the laser cell between the deposition of each
layer.
Eddy current, ultrasound signals generated by lasers, thermal patterns and optical methods for surface distortion
measurement technologies will be evaluated, developed and the performance established for the range of defects and sizes
required."

Field of science

  • /natural sciences/physical sciences/acoustics/ultrasound
  • /natural sciences/physical sciences/optics/laser physics

Call for proposal

FP7-SME-2011
See other projects for this call

Funding Scheme

BSG-SME - Research for SMEs

Coordinator

TWI LIMITED
Address
Granta Park Great Abington
CB21 6AL Cambridge
United Kingdom
Activity type
Research Organisations
EU contribution
€ 84 227
Administrative Contact
David Hamper (Mr.)

Participants (7)

BYTEST SRL
Italy
EU contribution
€ 323 409
Address
Via Pisa 12
10088 Volpiano
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Franco Baratta (Mr.)
TECNITEST INGENIEROS SL
Spain
EU contribution
€ 260 688
Address
Calle Ciudad De Frias 1-Nave 4
28021 Madrid
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Diego Florez (Mr.)
LPW Technology Ltd
United Kingdom
EU contribution
€ 208 300
Address
Keckwick Lane Vanguard House Daresbury Science & Innovation Campus
WA4 4FS Daresbury
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Philip Carroll (Dr.)
POLKOM BADANIA SP ZOO
Poland
EU contribution
€ 165 950
Address
Uk Ignacego Krasickiego 35
02 611 Warszawa
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Ella Schabowicz (Ms.)
KINGSTON COMPUTER CONSULTANCY LIMITED
United Kingdom
EU contribution
€ 21 750
Address
Worship Street 28-30 Crystal Gate
EC2A 2AH London
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Baksheesh Kaur (Ms.)
UNIVERSITA DEGLI STUDI DI PALERMO
Italy
EU contribution
€ 31 250
Address
Piazza Marina 61
90133 Palermo
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Maria Graziella Giaccone (Dr.)
TOYOTA MOTOR EUROPE NV
Belgium
EU contribution
€ 27 126
Address
Bourgetlaan 60
1140 Brussel
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Andrew Willett (Dr.)