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  • Periodic Reporting for period 1 - 4D hybrid (Novel ALL-IN-ONE machines, robots and systems for affordable, worldwide and lifetime Distributed 3D hybrid manufacturing and repair operations)

4D hybrid Report Summary

Project ID: 723795
Funded under: H2020-EU.

Periodic Reporting for period 1 - 4D hybrid (Novel ALL-IN-ONE machines, robots and systems for affordable, worldwide and lifetime Distributed 3D hybrid manufacturing and repair operations)

Reporting period: 2017-01-01 to 2018-06-30

Summary of the context and overall objectives of the project

From aeronautics to oil & gas, complex metal parts embrace major challenges across their lifecycles from the green field intensive manufacturing to the numerous maintenance and repairing operations worldwide distributed. The synergic combination of additive and subtractive processes could overcome individual shortcomings, going beyond the simple succession of steps. 'Plug and produce' modular approach is a key factor to success for such hybridization. In this scenario, 4D will deliver 4 disruptive breakthroughs:
•A set of four elementary modules specifically designed for AM that embed the control and monitoring systems which can be integrated on new or existing concepts of machines
•A new concept of CNC, constituting a high level sw layer which can be integrated on the top of commercial CNCs
•A validated process model to fully exploit the synergistic interactions among elementary processes
•A dedicated 4D Engineering CAD/CAE/CAM Platform, which covers the lifecycle of the reference product family where multiple processes and hybrid resources are integrated for the (re)manufacturing stage.
Innovation will be physically demonstrated at three possible levels of hybridization:
•Modules - Small hybrid modules, integrated on new special machines, focusing on portable units for certified in-situ repair operations
•Hybrid Machines – Hybridization on existing robots and machines
•Production lines - Hybridization of a flexible production line focusing on new concepts for AM mass production

4DHybrid’s ground-breaking target is to reduce by 30% the lifecycle cost of finished components manufactured by 4DHybrid modules, compared to current market prices of AM components.

4DHybrid will enhance European leadership in AM technologies by exploiting results from past and on-going projects (mainly Borealis and Corsair), involving leading companies in the metal working sector (PE part of Prima Industrie, Comau, Siemens), leverage innovation by European SMEs (3D-NT, Iris, Ramteid) and target the global market by involving in the consortium end users and potential customers from America and Africa (and Asia in the Interest Group) with the support in communication and dissemination by MCI-Benelux.

4DHybrid will boost the first worldwide AM cluster where all the major players and initiatives will be partnered to promote global actions to support the industrially structured adoption of new hybrid technologies.

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

"In WP2: Product Design by Technology and 4D Engineering Platform
Collected information about end-user requirements
Created use case maps depicting the existing MRO process
Identified and validated a series of opportunities arising from 4D Hybrid for each end user
Synthesised reference scenarios
Identify materials and typologies of damages
Design a series of parametric test features and test parts
Formalize design variables
Validate with technology providers & end users
Design Round Robin parts
Determine KPIs for each case
Completed screen flows for user interface
Detailed user interaction charts
Implementation of Engineering platform
In WP3: Process design and CAx
KPI identification and key parameter identification for each deposition process
Initial process benchmarking to establish fundamental relationships
Initial material depositions
Sample production for DED & CS
Powder characterisation
Microstructural analysis to map Product KPI/parameter relationships
Integration of the C++ mathematical model in Simulation engine
Prototype feedback control system with laser-line scanner
In WP4: Design and configuration of the 4D modules
New 3D technologies after using different laser sources came to the conclusion that the only remaining choice was the spatial multiplexing of two sources suitable for ablation and DED
The hyperspectral system had been designed around 4 channels for infrared imaging, on axis pyrometer, visible camera and UV light detection
This hyperspectral system attaches to the scanner via the 45° folding mirror
The whole system including multiplexer, optical chain, sensors and beam expander has been planned to be integrated into the existing 5 axis system
Deposition modules
The Mobile Platform
DED process model
DED process head model
DED thermal models
WP5: Design of the vision and sensing system
Start of development for a customized SoC camera platform based on an open-source project to be integrated into the process environment and to support the various vision use-cases
Concept improvements and implementation of further modules for the automation bus software “open4DHAB” providing a flexible and real-time service infrastructure for communication and interaction between heterogeneous sensors
The key parameters, values, and features for melt pool monitoring have been identified, the evaluation and split processing of algorithms for calculating these parameters and values and for extracting the required features was started
Pre-selection of available and suitable industrial grade marker-less 3D scanning systems. Preliminary 3D scans on already available 4DHybrid parts and further demo parts
WP6: Adaptive automation and CNC
Demonstrator #1 is now ready to execute Part-program coming from CAx chain and written with the syntax planned for this activity
Demonstrator #2 can run and execute a cold spray process
Demonstrator #3 configuration is completed and planned
The CNC developed by PrimaElectro is now ready to run in a 4D Hybrid environment
Process optimization at different time scales
Adaptation of machine settings to variations in product designs, requirements, materials and any other time-varying condition
WP7: Closed loop on line CAx infrastructure
Preliminary software tools have been selected. The integrability of these software tools into the process and sensing system have to be checked
A number of tests have been performed by considering the new tool path input format with multi-axis programming and interpolation of the tool center point (TCP) as well as at machine coordinates
WP10: 4D Dissemination and exploitation
T10.1 - T10.2 - T10.3
Publications/Media package
Social networks
The DEP & CSC.

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 expected impact:
- new generation aerospace, oil & gas complex products and power generation sector
- efficient additive and subtractive laser based manufacturing sectors
- next generation of machinery
Scientific impact:
- Introduction of a high energy efficient compact hybrid laser source module
- Integration of highly heterogeneous manufacturing technologies
- Design of 4D modules to be integrated on standard manufacturing resources with zero overhaul of the mechatronics
- Adaptive monitoring, CAx chain and control
Technical impact:
- Hybrid Machine
- Production lines
- Possibility to manufacture large components
- High powder efficiency
- High energy efficiency
- Higher superficial quality
Environmental and social impact:
- Reduction of the energy and resources consumption thank to innovative deposition strategies
- Compensation of the CO2 produced during the project with implant of a number of trees that ensures the carbon offset
Commercial impact:
- Reduction of time to market of products
- Unique Selling Point is the reduction of ramp up and of faulty parts in 4DHybrid process
- Reduction of production cost of products

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