Net-shape joining technology to manufacture 3D multi-materials components based on metal alloys and thermoplastic composites

Objective

ComMUnion enables productive and cost effective manufacturing of 3D metal/ Carbon Fibre Reinforced Thermoplastic (CFRT) multi-material components.
ComMUnion will develop a novel solution combining tape placement of CFRTs with controlled laser-assisted heating in a multi-stage robot solution. High-speed laser texturing and cleaning will overcome the limitations of current joining technology to provide greatest performance joints. ComMUnion will rely on a robot-based approach enabling on-line inspection for layer-to-layer self-adjustment of the process. Moreover, tools for multi-scale modelling, parametric offline programming, quality diagnosis and decision support will be developed under a cognitive approach to ensure interoperability and usability.
ComMUnion will address the following key innovations:
- Texturing and cleaning based on high speed laser scanning for surface condition.
- High-speed spatially resolved control of surface temperature profile.
- Multi-scale metal/CFRP modelling, self-adaptive process control, and quality diagnosis based on multimodal active imaging.
ComMUnion approach will decrease by 30% the consumption of titanium and boron steel, (costly alloys requiring critical materials). Besides, reinforcement of textured metallic surfaces with CFRT tapes will increase mechanical performance of multi-material components over 30% without cost increase.
Manufacturing of two pilot-cases for automotive and aeronautics will demonstrate the scalability of the joining process. It will be possible trough a consortium with a strong involvement of industrial partners (73% of which 55% are SMEs). The outline of the business plan ensures the exploitation of the project results. With a target market of 2.000 companies and a fair estimate of 2% market penetration (5 years after the commercialization start), ComMUnion will result in 40M€/year incomes.

Fields of science

• engineering and technologymaterials engineering
• natural scienceschemical sciencesphysical chemistrythermochemistry
• social scienceseconomics and businessbusiness and managementcommerce

Keywords

• Multi-material metal-thermoplastic composites parts
• laser-assisted tape placement joining system
• multi-scale modelling
• laser surface texturing
• automated inspection
• Real Time control
• recycling

Programme(s)

• H2020-EU.2.1.5. - INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced manufacturing and processing Main Programme
• H2020-EU.2.1.5.1. - Technologies for Factories of the Future

Topic(s)

• FoF-12-2015 - Industrial technologies for advanced joining and assembly processes for multi-materials

Funding Scheme

Coordinator

Participants (16)