A Productive, Affordable and Reliable solution for large ......Tecnalia Research & Innovation Standardisation activities Signed an agreement as CEN Liaison Organization for participation

FoF Community Day 16/05/2017, Brussels

Dr. Amaia Alberdi Tecnalia Research & Innovation

A Productive, Affordable and Reliable solution for large scale manufacturing of metallic components by combining laser-

based ADDItive and Subtractive processes with high Efficiency



Project Summary

• START DATE: 1st October 2016 • DURATION: 36 months • Coordinator: Tecnalia Research & Innovation • Budget: 3,761,403€

OBJECTIVE: To rationalize, to structure and to make available the tools for combining two antithetical processes: Laser Metal Deposition (LMD) and Machining (milling and turning)



Consortium



Hybrid ZVH 45/1600 ADD&PROCESS Machine

A

C

B

X

Y

Z

High productivity 5-axis machining center, with fixed table and mobile column architecture -Turning with horizontal and vertical plate -5-axis machining with A+B and B+C axes -Additive manufacturing by Laser Metal Deposition

Machine available at Tecnalia’s facilities

A development between: IBARMIA: Machine manufacturer, SME TECNALIA: Research center UNIVERSITY OF BASQUE COUNTRY

Specifications

X/Y/Z Courses 1600/800/900 mm

Laser Source Rofin FL030mm (FFC/FFS) fiber laser-Yb:glass

Laser Power 3 kW

Laser Head Precitec YC52 4 stream

Control Siemens 840D



Expected results

Database for different materials: Definition of process parameters for each material AISI 304L, Inconel 718, Hastelloy X, coating materials (Stellite 6, Colmonoy and

Eutrolloy 16606)

1

Manual image processing

Python Ab

Ac

H

b W

P1, P2 identification: • Direct identification • Polynomial regression of clad edges.

Geometrical characterization

Mechanical characterization: Hardness, tensile and fatigue testing, etc…



Expected results

Database for different materials 1

Zone A (1st track) Zone B (Middle track) Zone C (Last track)

P = 700 W V = 900

mm/min F = 50 %

Spot ~1.3 mm d = 13.7 mm

POROSITY

31.6 gr/min / Power=2500 W

1) 750 mm/min

2) 1000 mm/min

3) 1250 mm/min

Microstructure analysis



Expected results

CAx for LMD + Machining: API (Advanced Programming Interface) integrated into NX for CAD/CAM module

2

Process virtual simulation Characteristics: Easy to use Integrated database

for different materials LMD and machining in

the same structure



Expected results

CAx for LMD + Machining: CAE module 2

Thermal field: LATHEM model

Prediction of geometry of the clad



Expected results

Smart LMD Head and Powder Feeder with integrated monitoring systems 3

IDM (In-process Depth Measurement) technology for distance measurment

Pyrometer/ Thermographic camera

Laser Scanner: geometry measurement

Powder flow



Expected results

Control loops for LMD 4



Expected results

Hybrid machine with integrated solutions and validated in two use-cases 5

Low pressure Turbine shaft

Rubber Extrusion Screw



Standardisation activities

Signed an agreement as CEN Liaison Organization for participation in CEN/TC 438 « Additive Manufaturing »

cooperation with AM-Motion project, FoF-05-2016 call: Support for the further development of Additive Manufacturing technologies in Europe,



Other projects related to AM

http://transfron3d.eu/en/

Characterization of Ti6Al4V parts manufactured by WAAM technology

http://www.bionic-aircraft.eu/

http://amazeproject.eu/

Characterization of Aluminium alloy parts manufactured by LMD technology

Producing high value-added parts trough additive manufacturing processes.

WAAM LMD












Contact

Thank you for your attention

www.paraddise.eu

[email protected]

http://www.paraddise.eu/

mailto:[email protected]

Documents

A Productive, Affordable and Reliable solution for large ......Tecnalia Research & Innovation Standardisation activities Signed an agreement as CEN Liaison Organization for participation