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EMUSIC Report Summary

Project ID: 690725
Funded under: H2020-EU.3.4.

Periodic Reporting for period 1 - EMUSIC (Efficient Manufacturing for Aerospace Components USing Additive Manufacturing, Net Shape HIP and Investment Casting)

Reporting period: 2016-04-01 to 2017-09-30

Summary of the context and overall objectives of the project

Introduction. EMUSIC was launched on March 31 2016 to assess the potential of several net shape processes for manufacturing components for aerospace. The 18 partners in the consortium, have the ability between them of manufacturing demonstrator components, of improving the overall control of the processes via modelling, of assessing microstructure and properties and finally of assessing the cost for each process for the identified components.

Problem being addressed. Current manufacturing is focussing on net shape processes and the problem addressed in this project is to compare the quality and cost of a number of selected components, made using different net shape process routes, so that industry could make an informed choice of which route is most suitable for these components. The selected components are illustrated below, which were identified by the end users, who also defined the mechanical properties, the surface finish and accuracy of the components and the process-routes they wished to assess.

Importance to society. Efficient low waste manufacturing is of paramount importance today with the ever-increasing pollution associated with inefficient manufacture. Net shape manufacture is a very important approach to improve the environmental impact of manufacturing.

Overall objectives. To investigate a range of net shape manufacturing processes with the aims of reducing waste, improving properties and reducing cost of aerospace components.

Please see components in figure 1.

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

At the halfway stage initial trials have been carried out to manufacture these components, with strong interactions between the modellers and the processors aimed at optimising the process-routes and reducing costs by making shapes as near as possible to net shape and thus minimising post-process machining. Examples of the current state of manufacture are shown in figure 2 for the gimbal. The process-routes used in this figure are laser powder bed and wire feed AM before and after machining. In both cases modelling has been used to optimise processing conditions.

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 future work in all areas is focussed on improving the dimensional accuracy of the components and in a few cases improving the mechanical properties so that they meet specifications. When the final processing details are selected the processors will define the cost of each process route. The aim is to produce the final demonstrator components by month 33 so that the end users can assess them and report on them at the final meeting scheduled for March 2019.

If these aims are achieved the end-users will benefit and similar work should be carried out on other components so that industry is more cost-effective and causes less waste and pollution.

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