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2
• Cost savings compared to current manufacturing processes • Lead time reduction compared to forgings • Performance enhancement through
Ø Replacement of e.g. castings by higher performance materials Ø Weight savings by topological optimisation Ø New materials Ø Mixed material systems
WAAM business drivers
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WAAM business driver – cost saving case studies - Bombardier rib
Design option Mass (kg)
BTF Cost (£k)
Cost red.
Original machined 20 12 16.2 - WAAM + machining 20 2.3 5 69%
Design option Mass (kg) BTF Cost (£k) Cost red.
Original, machined 36 12 1.6 -
WAAM + machining 36 2.3 0.7 55%
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WAAM systems - where we are aiming - HELP!
Aluminium: • 14 months for
forging • 4 months for
machining • 90% waste
Titanium: • 10 times worse
problems
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WAAM – major technical challenges and activities
• System development - CAD drawing to part • Software and full automation
• WAAMDesign • WAAMSoft • WAMMCtrl • WAAMAPIs
• Hardware • Process monitoring • Fault detection • Component cooling
• New materials and combinations • High strength aluminium alloys • Superalloys • Refractory metals • Maraging steels
• In process NDT • Qualification – Q3
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CAMSo'ware• Toolpathplanning• Intelligentpar//oning
• Buildstrategyalloca/on
• Interfacemanagement
• Layerheightcontrol
• BuildsequenceGUI
• Autobuildstrategy
• Control
Performance• Tensile• Fa/gue• Fracturetoughness
• Crackpropaga/on
• Corrosion• Effectofdefects
WAAMMat – Technical Programme Overview
Processes• WAAMvariants• Processalgorithms• Buildstrategies• Higherbuildrates• Increasedfidelity• Wallwidthcontrol• Compensa/onstrategies
• WLAMandWLAAMOtherprocesses• 2.5Drolling• Alternatecoldworkmethods
• Grainstructuremeasurement
• Hybridmanufacture• IntegratedNDT• Defectrepair
New• Highstrength
aluminium• Refractory
metals• Maragingsteels• Superalloys• Metalfoams• MMCs• LowCTE
materials• Mixedmaterial
systems
Hardware• SoRplasma• Precisionwirefeeding
• Localshielding• Ruggedisa/on• Processmonitoring
• Controlsystems• Robo/csystems• Machinetools• Largestructures• Mul/processes
Commercialsystems
WAAMMatTechnicalProgramme
SystemDevelopment DesignToolsMaterials
MatureWAAM WAAMIndustrialApplicaCons
Qualifiedmaterials
OpCmisaCon• CADtoCAM• Hybridmanufacturetool
• Knowledgeexpertsystem
• Computeraidedplanning
Designcapability
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CAMSo'ware• Toolpathplanning• Intelligentpar//oning
• Buildstrategyalloca/on
• Interfacemanagement
• Layerheightcontrol
• BuildsequenceGUI
• Autobuildstrategy
• Control
Performance• Tensile• Fa/gue• Fracturetoughness
• Crackpropaga/on
• Corrosion• Effectofdefects
WAAMMat – Technical Programme Overview
Processes• WAAMvariants• Processalgorithms• Buildstrategies• Higherbuildrates• Increasedfidelity• Wallwidthcontrol• Compensa/onstrategies
• WLAMandWLAAMOtherprocesses• 2.5Drolling• Alternatecoldworkmethods
• Grainstructuremeasurement
• Hybridmanufacture• IntegratedNDT• Defectrepair
New• Highstrength
aluminium• Refractory
metals• Maragingsteels• Superalloys• Metalfoams• MMCs• LowCTE
materials• Mixedmaterial
systems
Hardware• SoRplasma• Precisionwirefeeding
• Localshielding• Ruggedisa/on• Processmonitoring
• Controlsystems• Robo/csystems• Machinetools• Largestructures• Mul/processes
Commercialsystems
WAAMMatTechnicalProgramme
SystemDevelopment DesignToolsMaterials
MatureWAAM WAAMIndustrialApplicaCons
Qualifiedmaterials
OpCmisaCon• CADtoCAM• Hybridmanufacturetool
• Knowledgeexpertsystem
• Computeraidedplanning
Designcapability
FullysupportedPar/allysupportedNotyetsupported
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WAAMMat Research Programme Structure
Stewart Williams Programme Director
Filomeno Martina Programme Manager
Jialuo Ding Lead Researcher
PhD Researchers (YB, SR, JH, KA, EE, XX, GM, FM)
Research fellows and associates (RF - GP, AM, TK, MM) (RA – PK, ZP, AC)
Academic Support (HL, PC, SG, RT, TC, WS)
Technicians (FN, NX, JP)
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WAAMMat Programme – Cranfield team
WAAMMatProgrammePartnerOverview
StewartWilliamsProgrammedirectorJialuoDingAutoma/on,soRware,partbuildingFilomenoMarCnaProgrammeManagerPaulColegroveColdwork,modelling,HelenLockettDesignanddesigntoolsSupriyoGangulyMetallurgyandF&DTRalphTatum,TomCarrolOp/calinstrumenta/onWojciechSuderWLAMandWLAAMJamesWidbourneControlsystemsYifanZhaoSignalProcessing
AcademicCranfield
11xPhDstudentsØ KwasiAyarkwa–novelAlstructuresØ GianroccoMarinelli–refractorymetalsØ JanHönnige–alterna/vecoldworkØ XiangfangXu–mixedmaterialsØ FlorentMichel–SoRwareforWAAMØ EloiseEimer–AldevelopmentØ PhilippeBridgeman-manufacturing
strategiesØ Alex–ProcessmonitoringandcontrolØ PhillipeTaiye–Fa/guebehaviourü 2xnewPhDstudentsstarCngJan
2017• VariousMScprojects
Students
GonzaloPardalCooling,localshielding,hybridlaserAnthonyMcAndrewMul/dimensionrolling,partbuilding,modellingPawelKurzsnikyControlsystemsandsoRwareZsoltPinterAldeposi/on,partandcomponentbuildingArmandoCaballeroNewmaterialsThomasKissingerOn-linesensingMichelangeloMortelloWLAMandWLAAMUzamiPartbuilding
Currently29peopleonprogramme+3technicians
ResearchersCranfield
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WAAMMat Programme - Academic Partners
InsCtuCon LeadinvesCgator Technicalarea Resource
ManchesterU PhilPrangnell, MaterialsScienceandModelling–Q3 1xres,1xPhD
UofNo]ngham SteveSharples On-linegrainsizemeasurement 1xres
IITBombay Karunakaran Integratedmachining,peening 2xPhD
HeriotWa_U AndrewMoore Flowvisualisa/on,processmonitoring 2xPhD
NEUniversityChina YuchunZhai Aluminiumwiredevelopment
OpenUniversity SanjooramPaddea Residualstresscharacterisa/on 1XRes
BathUniversity StephenNewman Processmonitoring 1xRes
CoventryUniversity XiangZhang Fa/gueandDT,effectsofdefects–Q3 1xRes,2xPhD
StrathclydeUniversity GarethPierce In-processNDT–Q3 1xRes
BristolUniversity HarryCoules Fa/gueandDT,effectsofdefects–Q3 1xPhD
SurreyUniversity Aluminiumwirequality–Q3 1xPhD
Del'University IanRichardson Thermalcyclesimula/ons,microstructure–Q3 1xPhD
IST LuisaQuin/no NDTanddesign 2xPhD
11 Academics + 18 researchers/students > 60 people in total working on WAAM
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• WAAMMat is a rolling technology programme incorporating a wide range of projects and activities • Industry sponsored research • Projects funded by outside
bodies (e.g. EU, EPSRC, TSB) • PhDs • Masters projects • Internally funded projects
• Currently 70 projects – total value >£4.5M,
WAAMMat Programme – features
IndustryEUUKNa/onalOther
14
WAAMMat Programme – Industry partner types
PartnerType Rights Requirements
Full • PerpetualroyaltyfreelicensetoallforegroundIPfromthecoreprogrammewhilstpartners
• Fullaccesstodetailofallresearchoutputsincoreprojects
• AccesstobackgroundIPneededtoexploitWAAM• Memberofindustryadvisorygroup
• Sponsorshipofresearchprojectswithminimumrequirementof£120kinatwoyearperiod
• SponsoredresearchmustformpartoftheWAAMMatcoreprogramme
Associate • Visibilityofallresearchoutputsfromthecoreprojects
• AccesstobackgroundIPneededtoexploitWAAM• Memberofindustryadvisorygroupbyinvita/ononly
• Contribu/ontotheWAAMMatbyforexample
• Non-coreresearchprojectsponsorship
• Smallerresearchprojectcontribu/on
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WAAMMat industry members
WAAMMatFull AssociateorcollaboraCve
UK Interna/onal UK Interna/onal
BAESystems LockheedMar/n CCFE VolvoTrucks
Globalrobots NEIMM Delcam Constellium
DSTL UTRC AirbusGroup Fanuc
GlenAlmond FMC PWP AirProducts
LindeGases AWE EWM
OfoFuchs Technicalarc Fronius
Thales SelectArc
Weir Bekaert
NormanFoster&P
Indiscussion
3Dsystems Roxel Boeing NorthropGruman
Keppel AirLiquid
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Basic WAAM Hardware
WAAM Basic System and IP
NC Controller
Motion System
Power Source
Material Supply
Additional Processes (e.g. Rolling, PDHT)
Additional Functionality
Finishing (Milling/Grinding)
Inspection (Shape/Defects
Feature identification
Geometric Data Input (3D CAD)
Process Parameters
Conversion to Layer Geometry (Slicing)
Machine Tool/ Robot Path Generation
Software and Process Data
Intellectual Property
Material properties
WAAM - IP
Design Handbook
Process Algorithms
Compensation strategies
Feature build strategies
Additional processes
Deposition geometries Build sequence
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WAAM Software
WAAM process procedure
CADmodelmodifica/onto
preforms
Pathplanningandpost-processingtorobot/CNCprogramme
Processmonitoringandcontrol
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WAAM Commercialisation – WAAM Systems and Services (WSS)
WSS
SystemIntegratorsSystemsupply
HardwareManufacturersHardwaresupply
WAAMSystems
WAAMServices
JobshopsBatch
manufacture
So'wareWAAMSoRWAAMCtrlWAAMDesignWAAMCost
HardwareWAAMShieldWAAMSenseWAAMCoolWAAMWork
PrototypingPrototypeparts
ConsultancyPartevalua/on• WAAM
manufacture• CostbenefitSystemdesign
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Potential WAAM systems under discussion
Type System FuncConality ApproximateSaleValue LikelysectorA Verylowcost
CNC• Cheapanaloguepowersource• LowcostCNC• Limitedso'warefuncConality• Limitedbuildvolume
£10k-£30k 3DprinCng,enthusiasts,educaCon
B Lowcost-highendrobot+digitalpowersource
• Al/Steels/Inconel/Etc.-GMAW• Simpleparts,shapesandfeatures• Mediumso'warefuncConality
(maybebespoke)
£60k–£300kHardwaretypical:£120kSo'waredependingonfuncConalitycancostupto£100k
Generalengineering,oil&gas,defence,
C1 Highcost-highendroboCcssystem(1ormorerobots)
• PlasmabasedincludingTi• 1ormorerobots• MulCpleprocesses-Integratedcold
work+machining+metrology+NDT• Highso'warefuncConality
£200k–£600kFor2robots:£250kandincludesmachiningheadsandtoolchangers
Aerospace,highvaluemanufacturing,energy,defence,repair
C2 MediumcostCNCbasedsystem
• Limitedbuildvolume(1m3)• LimitedfuncConality• PlasmabasedincludingTi• Highso'warefuncConality
£250k–£750k
Aerospace,highvaluemanufacturing
D Highcost-highendCNC(roboCc+CNC)
• Integratedcoldwork+machining• NDT+metrology• Allmaterialsincl.Ctanium• Highso'warefuncConality
£0.5–£2million Aerospace