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  • Periodic Reporting for period 1 - COMBILASER (COMbination of non-contact, high speed monitoring and non-destructive techniques applicable to LASER Based Manufacturing through a self-learning system)

COMBILASER Report Summary

Project ID: 636902

Periodic Reporting for period 1 - COMBILASER (COMbination of non-contact, high speed monitoring and non-destructive techniques applicable to LASER Based Manufacturing through a self-learning system)

Reporting period: 2015-01-01 to 2015-12-31

Summary of the context and overall objectives of the project

COMbination of non-contact, high speed monitoring and non-destructive techniques applicable to LASER Based Manufacturing through a self-learning system (COMBILASER) an European research project coordinated by HIDRIA AET that has been chosen for co-financing from the European Commission by the Horizon 2020 Factories of the Future call.

The vision of COMBILASER presents a great development leap forward in terms of a pioneering approach that combines all aspects of defect avoidance in welding and cladding processes into an integral or holistic concept.

The vision of the partners of the COMBILASER project is to create a solution that will with its use-cases serve as a model for different branches of European industry (automotive, aeronautic /aerospace, railway, electronics, capital goods etc.) on how to address the ever more demanding standards in the industry when manufacturing products using laser welding / laser melting or cladding processes.

By integrating the industrial laser process with a seamless set up and a Self-Learning module, the COMBILASER project aims to minimize human expert interveNtion and in doing so reduce process optimization loop for new applications. When taking into account the ever changing market rules and increased manufacturing flexibility demands from customers, the COMBILASER project aims to create a solutions that can act as an industrial driver from many European industries in the future.

In its three industrial use-cases ranging from automotive (welding of a pressure-sensor glow plug for diesel motors), capital goods (laser welding of flame sensor device) and oil&gas industry (valve cladding process) divide the main objective of COMBILASER into following sub-objectives:

• Productivity increase of about 35 % in gas valves repairing process due to required re-works reduction (cladding layer and base material cracking avoidance).
• Allow to take to the market new generation of pressure sensor glow plug 45 % faster thanks to the avoidance of cracking appearance using the developed SLS.
• Reduce time-to-market of new flame device sensors by at least 45 % thanks to acquired knowledge in previous products manufacturing thanks to SLS.
• Reduction of scrap parts and wastes in new pressure sensors (for glow plugs) manufacturing processes of up to a 50 % through laser welding monitoring and process parameters control.
• Decrease the number of flame sensor defective parts up to 75 % thanks to the continuous increase in LBW process knowledge.
• Zero failure parts delivered to the customers in all of the use cases making use of in-line advanced NDTs to 100% of manufactured parts.

COMBILASER consortium brings together a consortium of 12 partners from 7 different European states. It is comprised of LEs, SMEs, R&D institutes and a university.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

COMBILASER project started with WP1 - Project Specifications: a clear definition of project Work Plan which includes all technical, project management and logistics, delivery of test samples – all have been successfully agreed and aligned between all project Partners.
At its conclusion the WP1 produced a deliverable - D1.1 – Project Specification document.

The second WP - Monitoring Techniques Development - covers the development of laser illumination, spectral monitoring system and a Thermographic monitoring system for laser manufacturing processes. Based on the requirements of the user cases (specified in WP1) and the general goals of the COMBILASER project the project partners designed and implemented a melt pool monitoring system using active laser illumination and a compact camera, a spectral monitoring system by configuring a sensor systems based on standard equipment by means of adapted optical band pass filters and special photosensitive detectors, synchronisation of the high-speed camera systems, development of coaxially observation unit, evaluation of camera images and first simulations of UCs.
Thus the WP2 produced three deliverables: D2.1 – Melt pool monitoring system, D2.2 – Spectral monitoring system and D2.3 - Thermographic monitoring system

In WP3 – NDT Techniques Development – development activities started on Active Thermography and Laser Ultrasonics but its deliverables and results have been delayed due to specific demands from industrial partners' use-case set-ups and some unfortunate equipment breakdown. The consortium looks to make up the lost time in the following months and will ensure that the unforeseen delays won't interfere with acivities performed in other WPs.

Activities of the project have been very active in WP4 - Self-Learning System Development. The partners developed the definition of Self-Learning System inputs and outputs (100% completed). The overall Self-Learning System development process is currently at 40% overall completion with the feature selection 100% complete, the modelling structure 60% complete and optimization/control not started yet. The COMBILASER consortium expects a publication at IEEE World Congress on CI 2016. A deliverable D4.1 - Definition of Self-Learning System was completed albeit with a small delay.

Work on WP5 – Integration of defined System on Laser-based Manufacturing Processes and WP6 – Validation and Demonstration of the integral Solution, has not started yet and is planned for the future.

Very good progress was made on the WP7 - Dissemination and Exploitation. The most important document in this WP is the PDER - Initial Plan for dissemination and Exploitation of Results. Extensive activities were done on this WP already in the first months in order to ensure quick and efficient promotion of the COMBILASER project in the interested public. Results of WP7 activities include a fully functioning project website (together with internal private intranet for project partners intended for project documentation exchange), designed corporate identity of the project (project documentation templates), dissemination material (poster, flyer), two official press releases, project news about project presentation at the various events (Trade fair, 4th International Symposium on Laser Ultrasonics & Advanced Sensing, Laser Innovation Event at the Laser World of Photonics,..).
Two deliverables were prepared for this WP: D7.1. – COMBILASER project website and D7.2 – Initial PDER.

The WP8 – Project Management, covers COMBILASER management activities. Work was mostly done via face-to-face meetings and teleconference sessions (TelCo). The COMBILASER Kick-of meeting (KoM) was held in Tolmin on January 20th and 21st 2015 and was hosted by COMBILASER project coordinator Hidria AET. The second consortium meeting of all partners was then held in Ordizia, Spain on 6th and 7th May and hosted by IK4-LORTEK.

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)

The COMBILASER project has already shown great potential to bring about breakthrough solutions in field of welding and cladding for the European industry. As the COMBILASER consortium enters its second year of the project the most important stages will begin to unfold and solutions will need to be thoroughly tested and prepared for final stemp of implementation and validation. The COMBILASER project industrial partners have already seen progress being made fat their UCs. At the same time the project gives all partners great possibility to to acquire new knowledge and get introduced in new consortia and initiatives under Horizon 2020 calls.

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