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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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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)
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
Consortium
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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…
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
Expected results
CAx for LMD + Machining: CAE module 2
Thermal field: LATHEM model
Prediction of geometry of the clad
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
Expected results
Control loops for LMD 4
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
Expected results
Hybrid machine with integrated solutions and validated in two use-cases 5
Low pressure Turbine shaft
Rubber Extrusion Screw
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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,
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
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
FoF Community Day 16/05/2017, Brussels
Dr. Amaia Alberdi Tecnalia Research & Innovation
Contact
Thank you for your attention
www.paraddise.eu