Our results

OUR THREE DEMONSTRATORS

A330NEO JACK ACTUATOR
BRACKET
A340 HYDRAULIC BLOCK A350XWB T-MOUNT-FITTING

BIONIC FEATURES

An automated and simplified design process has been determined for biomimetic lightweight structures. Quality gates were and will be transferred to an automated process work-flow. A method for optimization and sizing of ALM parts with justified structural integrity is defined. A toolset for a commercial 3D-CAD software is being developed, which allows a seamless workflow from the part design to the ALM pre-processing and post processing steps. It will enable an automated feature recognition based on a catalogue of parameterized biomimetic structures.

MATERIALS AND PROCESSES

The induction coupled plasma (ICP) powder production process has been set up for standard and high-strength Al-Li alloys. Feasibility of processing of Al-Li was proven using gas atomized powders. Further Al-Li alloy variants will be produced by ICP and gas atomization and comparatively evaluated.

Optimized laser beam intensity profiles have been identified by innovative 2D simulation of the melt pool Results show potential for more homogenous melt pool development and more precise beam shape conduction. The ALM test rig has been developed and set up, and experimental validation of the models has started. The work performed shows a potential increase of productivity by 30% and increase of energy efficiency by 35%.

QUALITY ASSURANCE

Requirements regarding the integrity systems and NDT method have been defined. Based on these, an in-line integrity system is being developed to validate the integrity of ALM parts directly after manufacturing. To be able to already check the integrity of an ALM part directly during the building process, an in-process integrity system is developed. To be able to check the condition of complex ALM parts in-service, innovative NDT methods are being developed, along with a simulation for life-time prediction based on actual part condition and defects.

AFTER SALES SUPPLY CHAIN

The overall applicability of ALM to the after sales supply chain has been explored, and new business models to reduce inventory, increase competiveness and increase market offering have been elaborated. Focus is on assessing regional production of ALM spare parts, and to define a lean end-to-end process for spare part supply. A significant reduction in inventory for spare parts should be achieved without any negative impact on the quality of the parts provided.

REPAIR AND RECYCLING

Cost-competitive repair procedures for parts manufactured by ALM and TS, as well as resource efficient recycling methods are developed. Large worn volumes shall be restored without effects on the microstructure and/or mechanical properties of the original parts. Repair procedures based on TS and LMD are validated on samples with representative complex geometries. Additionally the recycling of ALM powders and parts to produce high-quality powders is planned.