ADDitive manufacturing of FLAP tracks based on laser w-ded process

ADDIFLAP project’s general aim is the development of a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new design of carriage system based in sliding pad concept, made using a self-lubricant MMC coating.

ADDIFLAP involves the following objectives:

• Development of simulation models and optimized manufacturing strategies will reduce the effort in reducing the distortion on the flap track support up to 50% regarding the trial-and-error approach. This will impact in the time to market, reducing even further the time from design to manufacturing.
• Flexibility (on design, enabling part consolidation…) provided by AM technologies (W-DED-LB) will enable to reduce the time to market into 20%.
• Reduction of 60% on material waste regarding conventional manufacturing is expected (Reduction of the BTF ratio).
• Reduction of 20-30% on component distortion will be achieved by combination of simulation, and optimization of WDED-LB process parameters and online monitoring & control developed in ADDIFLAP Project.
• The sliding carriage system will increase the component flying hours for a conventional Business Jet in a factor of two regarding conventional roller system.

The technology developed in ADDIFLAP will enable the design of a multifunctional flap which combines aileron and high lift functions in one flap body having direct impact on weight reduction.