Development of a comprehensive methodology applied to large-format parts obtained by additive manufacturing for the aeronautical sector GRANADA (CPP2021-008841)
Additive Manufacturing (AM) technologies are transforming how products are designed, manufactured, and delivered. AM enables flexible, on-demand production, previously unthinkable functionalities and designs, and savings in manufacturing materials and tools.
Although there are AM technologies applicable to metals with more industrial implementation, such as laser powder bed melting (PBF), direct energy deposition (DED) processes offer specific advantages such as: (1) possibility of manufacturing medium-large sized parts; (2) possibility of repair and reconstruction of specific parts of a part; (3) use of “tailor-made” facilities from broad-spectrum industrial components and existing laser facilities; (4) possibility of manufacturing multi-material, multi-functional and gradient function components; and (5) higher deposition rates.
However, for the widespread industrialization of AM, it is necessary to develop digital tools to predict, correct, and manage the manufacturing of defect-free printed parts. This involves the use of tools such as topology optimization (TO), design for additive manufacturing (DfAM), monitoring technologies, and finite element simulation tools. This deficiency is exacerbated for DED technologies focused on large-format parts whose thermal history and prediction of their mechanical behavior within an acceptable computing time is very complex.
For all these reasons, the GRANADA project aims to provide a comprehensive solution for the manufacturing of large-format parts with complex geometries and high-value-added materials used in the aeronautical sector, using WLAM (Wire Laser Additive Manufacturing) technology. This comprehensive solution will encompass everything from part design and optimization, laser AM process simulation, and the implementation of process monitoring systems to the functional validation of manufactured structures. This will be validated through two demonstrators using two high-value-added materials, Titanium and Invar, used in the aerospace sector.
The GRANADA project aims to respond to the demands of this industry by being part of one of the technological priorities of the call included in the State Plan for Scientific and Technical Research and Innovation (PEICTI) 2021-2023 and the corresponding strategic action AE4: Digital world, industry, space and defense, whose strategic lines are aligned with GRANADA in the area of digitalization of processes, mathematical modeling and analysis, and new materials and manufacturing techniques.
The project is based on two fundamental pillars that must be validated jointly:
- Simulation of the WLAM process for large-format parts, to help define optimal manufacturing strategies and WLAM process parameters for the development of large-format parts. Models based on Finite Element Methods (FEM) will be used to predict distortion behavior.
- Development of the WLAM additive manufacturing process for high-value-added materials used in the aeronautical sector. The main technology underlying the GRANADA project is laser-assisted direct metal deposition using wire as a filler material (WLAM). In the aeronautical and aerospace industries, the use of reactive materials such as titanium is common, which requires an inert chamber during processing to prevent oxidation. To assess proper inerting, a monitoring methodology will be developed to evaluate the elemental content (especially oxygen) present in the plasma generated during laser metal processing. This technology is not only applicable to closed-chamber atmosphere control but can also be extended to localized protective atmosphere control, which is the standard approach for WLAM processing of non-reactive materials.
To achieve its main objective, GRANADA relies on a complementary multidisciplinary consortium that combines the experience and knowledge of specialized entities in different complementary areas: AM process simulation, AM process development, laser processing technology, monitoring systems that guarantee the quality of manufactured parts, development of digital solutions for the entire production process, automation, etc.
- CiTD, a Getafe-based company and leader in the provision of comprehensive product innovation and engineering services, was founded in 2015 as a continuation of the activity that ITD Engineering had been carrying out for more than a decade in the aerospace and defense sector.
- CATEC is a technology center established and managed by the Andalusian Foundation for Aerospace Development (FADA) specializing in additive manufacturing technologies.
- AIMEN, located in O Porriño (Pontevedra), is an Innovation and Technology Center with a high specialization in the field of materials and advanced manufacturing technologies.
The GRANADA project is funded by the 2021 Public-Private Partnership call for proposals. It is expected to last 36 months, covering four different annual periods, between September 2022 and August 2025, with a total budget of €559,939.
CONSORTIUM:
Project CPP2021-008841 funded by:
«Granada Project CPP2021-008841, funded by MCIN/AEI/10.13039/501100011033 and by the European Union “NextGenerationEU”/PRTR»