FANTASIA - Flexible and Near-Net-Shape Generative Manufacturing Chains and Repair Techniques for Complex Shaped Aero Engine Parts
Overview
Background & policy context:
The aim of FANTASIA was to contribute towards winning global leadership for European aeronautics by developing new flexible and near-net-shape additive manufacturing chains and repair techniques using laser metal deposition (LMD) and direct laser forming (DLF) processes. These techniques, in combination with conventional manufacturing processes, provided the possibility to realise a breakthrough in the manufacturing of aero-engine parts. In particular, the following potential could be achieved:
- New design possibilities using the nearly unlimited geometrical freedom of DLF;
- Decrease time efforts in the whole life cycle of a part in the design and/or redesign phase, subsequent manufacturing and the repair phase;
- Savings in production and raw material costs due to reduced time effort and raw material quantity to be used in generative manufacturing;
- Processability of conventional nickel and titanium base alloys as well as upcoming advanced materials like TiAl and Udimet 720.
Three major aero engine and component manufacturers (OEMs), two repair excellence centres as end users, six industrial partners as systems engineering and powder providers together with seven universities and research institutes have joined their multidisciplinary expertise and resources in materials science, laser manufacturing technique and sensorics and in design, manufacturing and repair of aero engine parts in the FANTASIA proposal.
Objectives:
The main project objectives were:
- Development of process layout for LMD to achieve the required characteristics with respect to material, part quality and economy;
- First time development of process layout for DLF to achieve the required characteristics with respect to material, part quality and economy;
- Development of heat treatment cycles before and after laser treatment to get microstructures and thermal stress fields that meet the mechanical properties;
- Determination of static and dynamic mechanical properties of the laser-processed and heat-treated samples together with correlation of these properties with microstructure and stress fields;
- First time workout of acceptance plus a non-destructive test (NDT) inspection criteria for LMD and DLF process (correlations between tolerable defects, microstructure, mechanical properties and process parameters);
- Support of the process development by simulation of temperature, stress fields and microstructure formation to predict process parameters and build-up strategies;
- Development of equipment for LMD and DLF processes:
- processing heads, including powder feeding nozzles and shielding gas units for 3D processing
- process chamber for DLF software
- for Computer Aided Design / Computer Aided Manufacturing (CAD/CAM) integration
- sensors and systems for on-line process control;
- New manufacturing and repair chains by combining conventional (e.g. casting, milling, joining) and laser-based techniques (LMD, DLF).
This will minimise the cost and lead-time due to reduced market response times from manufacturing to design and design to manufacturing. The technology developed will trigger a quantum step in cost reduction for design or re-design, manufacturing and repair of new or existing aero engine parts.
Methodology:
The work was divided into work packages as follows:
WP1
In WP1, the test pieces and the additives for LMD and DLF were manufactured. The additives (powder and wire) were characterised.
WP2
The aim of WP2 was the FE modelling of LMD and DLF processes to generate input for the process development (WP3). The main focuses were the calculation of the temperature and stress fields, as well as the microstructure formation in dependence of process parameters and part geometry.
WP3
In WP3, the process layout for LMD and DLF were developed for different materials and part geometries. A further aspect in WP3 was the development of suitable heat treatment procedures after LMD and DLF processes.
WP4
In WP4, hard- and software for both techniques were developed, modified and tested.
WP5
For quality assurance and reliable LMD and DLF, process monitoring and on-line process control systems were developed and tested in WP5. The focus of this WP was the development of on-line process control methods.
WP6
Simultaneously with the process engineering in WP3, a geometrical and metallurgical examination of the test pieces was carried out in WP6.
WP7
In WP 7, test pieces from different materials for mechanical testing were fabricated with the suitable parameters determined in WP3.
WP8
To ensure the required and defect-free structure of the processed parts, non-destructive tests (NDT) had to be carried out (WP8).
WP9
Based on WPs 2-8, demonstration parts were repaired and manufactured in WP9 using the developed techniques and process chains. This work package included the heat treatment, the final machining, NDT inspection and the mechanical tests.
WP10
In WP10, a technical and economical assessment of the results were carried out. An additional essential aspect was working out the acceptance and NDT inspection criteria for LMD and DLF.
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