High Deposition Rate Additive Manufacture of Complex Metal Parts (HiDepAM)
Lead Research Organisation:
CRANFIELD UNIVERSITY
Department Name: School of Water, Energy and Environment
Abstract
Additive manufacturing (AM) is a process of building a component layer by layer. In a simplified manner, it can be described as 3D printing of a component. The technology is important because it is logistically and conceptually extremely simple with major benefits. For example it would lead to significantly reduced material and energy use and manufacture of structures such as aircraft. Lowering of material wastage is an important issue as presently the aerospace sector machines out complex shapes from regular shaped structures. This causes significant wastage and a very high buy to fly ratio, i.e. A large amount of material needs to be purchased compared to that which goes on the aircraft. AM is able to create complex component architectures which would supplement the advancement in soft design technology. Therefore, it is no wonder that AM technique has been identified as one of the transformational technology for the future manufacturing sector.
This project is tackling two major barriers to implementation of AM technology for applications such as making aircraft. These are the very high cost of the process and the properties of the material that is being deposited. In the present programme the multi-disciplinary team seeks to investigate the development of AM processes that are overcome the barriers. This includes a new AM process based around the use of the laser combined ways a new method of adding material. We are also developing a new process to go with the AM process which transforms the properties of the material so that it is similar to the material currently used on aircraft. This new process uses techniques like rolling to introduce cold work into the metal; this changes the structure of the material at the microscopic level. Finally manufacturing of complex shapes, out of position (not vertical down) and multi-axes deposition and integrated machining will be evaluated for production of near net shape from a single process. The research programme would also study the feasibility of developing an innovative and non-destructive way of online process control of microstructure by Spatially Resolved Acoustic Spectroscopy (SRAS) technique. The consortium is carefully formed with complimentary knowledge base between the partners so that a significant progression can be made within the project span. This cross continental activity will help in leveraging the tacit knowledge base through regular visits; web based discussions and investigator exchange programme. The project is expected to solve the major issues identified in AM Technology, leading to its early application in industry.
This project is tackling two major barriers to implementation of AM technology for applications such as making aircraft. These are the very high cost of the process and the properties of the material that is being deposited. In the present programme the multi-disciplinary team seeks to investigate the development of AM processes that are overcome the barriers. This includes a new AM process based around the use of the laser combined ways a new method of adding material. We are also developing a new process to go with the AM process which transforms the properties of the material so that it is similar to the material currently used on aircraft. This new process uses techniques like rolling to introduce cold work into the metal; this changes the structure of the material at the microscopic level. Finally manufacturing of complex shapes, out of position (not vertical down) and multi-axes deposition and integrated machining will be evaluated for production of near net shape from a single process. The research programme would also study the feasibility of developing an innovative and non-destructive way of online process control of microstructure by Spatially Resolved Acoustic Spectroscopy (SRAS) technique. The consortium is carefully formed with complimentary knowledge base between the partners so that a significant progression can be made within the project span. This cross continental activity will help in leveraging the tacit knowledge base through regular visits; web based discussions and investigator exchange programme. The project is expected to solve the major issues identified in AM Technology, leading to its early application in industry.
Planned Impact
Manufacturing has now been identified as one of the potential vehicle which can positively impact the economic growth of UK. Return on investment in manufactruing has always been positive and consistent. It is also one of the sector where growth can be sustainable with a profound impact on people's life. Additive Manufacturing (AM) is a digital tool-less manufacturing technique that will have profound impact on the future of high value and advanced manufacturing sector. At present the whole segment of AM, including machine tools, material sales and associated services, is worth $1.9 billion. However, the segment is growing aggressively across the world. The double digit growth figure in recent years indicates that by 2020 even with the present growth rate this segment of manufacturing will be worth $7.5 billion. However, if the technology readiness level (TRL) can be advanced and commercial barriers eliminated it has been predicted that the AM has potential to become a sector worth $100 billion. In recent years in UK a total of £90 million (including private and public sector) has been invested to advance the technology readiness level of AM. From all the investments and growth figure it is obvious that this multi-disciplinary research programme is timely and successful completion would have significant impact on the TRL. The growth of this sector implies that it would also result in creation of jobs in significant numbers across the globe. Individual specifically trained in this area of manufacturing will be needed which will drive creation of academic courses. AM technology also reduces material waste, increases energy efficiency and has the potential of developing complex design efficient structures. Therefore, development of AM technology as a manufacturing tool will have a very strong and positive impact in every sphere of human activity.
Organisations
- CRANFIELD UNIVERSITY (Lead Research Organisation)
- Global Robots (Collaboration)
- Central Mafacturing Technlogy Instititute (Collaboration)
- Arm Limited (Collaboration)
- Bekaert (Collaboration)
- Federal University of Amazonas (Collaboration)
- BOMBARDIER INC. (Collaboration)
- Defence Science & Technology Laboratory (DSTL) (Collaboration)
- Lockheed Martin (United States) (Collaboration)
- Air Products (Collaboration)
- ITS (United Kingdom) (Collaboration)
- United Technologies Research Center (UTRC) (Collaboration)
- GKN (Collaboration)
- National Institute for Materials Sciences (Collaboration)
- BAE Systems (United Kingdom) (Collaboration, Project Partner)
Publications
Bob E S
(2015)
STABILISATION OF MIG ARC WELDING OF TITANIUM ALLOYS
Donoghue J
(2016)
The effectiveness of combining rolling deformation with Wire-Arc Additive Manufacture on ß-grain refinement and texture modification in Ti-6Al-4V
in Materials Characterization
Fayolle RC
(2016)
Cryogenic cooling of wire + arc additive manufacture
Gu J
(2016)
The strengthening effect of inter-layer cold working and post-deposition heat treatment on the additively manufactured Al-6.3Cu alloy
in Materials Science and Engineering: A
Martina F
(2015)
Microstructure of Interpass Rolled Wire + Arc Additive Manufacturing Ti-6Al-4V Components
in Metallurgical and Materials Transactions A
Martina F
(2016)
Residual stress of as-deposited and rolled wire+arc additive manufacturing Ti-6Al-4V components
in Materials Science and Technology
Pardal G.N.R
(2017)
Out of position deposition of TI64 by WAAM
Description | By introducing a mechanical working step after each layer of deposition during 3D printing of metals much better mechanical properties can be achieved. High deposition rate additive manufacture has been developed. This is with both multiple wire and shaped wire configurations which are both new techniques. |
Exploitation Route | Development of WAAM systems that include cold work to improve material properties enabling much greater exploitation of 3D printing of metals by industry |
Sectors | Aerospace Defence and Marine Energy Manufacturing including Industrial Biotechology |
URL | https://waammat.com/ |
Description | A new company WAAM3D has been set up that will commercialise some or the research outputs from this project or from projects that arose from this work |
First Year Of Impact | 2018 |
Sector | Manufacturing, including Industrial Biotechology |
Impact Types | Economic |
Description | AM Strategy |
Geographic Reach | National |
Policy Influence Type | Contribution to a national consultation/review |
Description | ATI Innovate funding |
Amount | £8,000,000 (GBP) |
Funding ID | 5041010 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 01/2018 |
End | 12/2020 |
Description | Direct industrial contract |
Amount | £78,000 (GBP) |
Organisation | Airbus Group |
Department | Airbus Operations |
Sector | Private |
Country | United Kingdom |
Start | 01/2017 |
End | 06/2017 |
Description | EPSRC Programme grant |
Amount | £5,746,005 (GBP) |
Funding ID | EP/R014574/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 04/2018 |
End | 04/2023 |
Description | ESA Contract |
Amount | € 2,500,000 (EUR) |
Organisation | ESA - ESTEC |
Sector | Public |
Country | Netherlands |
Start | 03/2017 |
End | 03/2020 |
Description | High Productivity Wire Arc Additive Manufacturing (HPWAAM) |
Amount | £1,220,291 (GBP) |
Funding ID | 53610 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 11/2020 |
End | 10/2023 |
Description | Industrial |
Amount | £120,000 (GBP) |
Funding ID | EMD3043V |
Organisation | Weir Pumps Ltd |
Sector | Private |
Country | United Kingdom |
Start | 09/2017 |
End | 09/2019 |
Description | Industrial contract |
Amount | £950,000 (GBP) |
Funding ID | EMD3034V |
Organisation | BAE Systems |
Department | BAE Systems Military Air & Information |
Sector | Private |
Country | United Kingdom |
Start | 12/2016 |
End | 04/2018 |
Description | Industrial contract |
Amount | £40,000 (GBP) |
Organisation | United Technologies Research Center (UTRC) |
Sector | Private |
Country | United States |
Start | 03/2016 |
End | 12/2016 |
Description | Industrial funding |
Amount | £140,000 (GBP) |
Organisation | Lockheed Martin |
Sector | Private |
Country | United States |
Start | 03/2016 |
End | 12/2019 |
Description | Industrial research project |
Amount | £880,000 (GBP) |
Funding ID | EMD3034V |
Organisation | BAE Systems |
Sector | Academic/University |
Country | United Kingdom |
Start | 11/2016 |
End | 08/2018 |
Description | Industrial research project |
Amount | £180,000 (GBP) |
Funding ID | EMD3039V |
Organisation | Schlumberger Limited |
Sector | Private |
Country | United States |
Start | 05/2017 |
End | 05/2020 |
Description | Industrial research project |
Amount | £120,000 (GBP) |
Funding ID | EMD3040Z |
Organisation | Northrop Grumman |
Sector | Private |
Country | United States |
Start | 08/2017 |
End | 08/2019 |
Description | Industry funding |
Amount | £22,000 (GBP) |
Funding ID | EMD4007V |
Organisation | Weir Pumps Ltd |
Sector | Private |
Country | United Kingdom |
Start | 01/2017 |
End | 07/2017 |
Description | Innovate UK |
Amount | £400,000 (GBP) |
Funding ID | 5041010 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 01/2015 |
End | 01/2017 |
Description | LASIMM |
Amount | € 4,800,000 (EUR) |
Funding ID | 723600 |
Organisation | European Commission H2020 |
Sector | Public |
Country | Belgium |
Start | 09/2016 |
End | 09/2019 |
Description | New Wire Additive Manufacturing (NEWAM) |
Amount | £5,886,209 (GBP) |
Funding ID | EP/R027218/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 05/2018 |
End | 06/2024 |
Description | Central Manufacturing Technology Institute, Bangalore |
Organisation | Central Mafacturing Technlogy Instititute |
Country | India |
Sector | Private |
PI Contribution | Training in additive methods. |
Collaborator Contribution | None. |
Impact | None yet. |
Start Year | 2016 |
Description | Ni superalloy deposition |
Organisation | Federal University of Amazonas |
Country | Brazil |
Sector | Academic/University |
PI Contribution | We provided facilities for multi layer deposition of Ni superalloys, and training in arc welding deposition. |
Collaborator Contribution | Provision of researcher and materials. |
Impact | None yet. Paper in preparation. |
Start Year | 2015 |
Description | Use of strip wire in additive manufacture |
Organisation | Bekaert |
Country | Belgium |
Sector | Private |
PI Contribution | investigation of the benefits of using strip wire |
Collaborator Contribution | provision of commercial grade strip wire to specific geometries |
Impact | none yet |
Start Year | 2016 |
Description | WAAMMat |
Organisation | Air Products |
Country | United Kingdom |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | Arm Limited |
Country | United Kingdom |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | BAE Systems |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | Bombardier Inc. |
Department | Bombardier Transportation |
Country | Germany |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | Defence Science & Technology Laboratory (DSTL) |
Country | United Kingdom |
Sector | Public |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | GKN |
Country | United Kingdom |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | Global Robots |
Country | United Kingdom |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | ITS United Kingdom |
Country | United Kingdom |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | Lockheed Martin |
Country | United States |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | National Institute for Materials Sciences |
Country | Japan |
Sector | Academic/University |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Description | WAAMMat |
Organisation | United Technologies Research Center (UTRC) |
Country | United States |
Sector | Private |
PI Contribution | We are running a collaborative research programme to mature wire + arc additive manufacture technology with many industry partners contributing direct cash to support the programme. The EPSRC award forms part of the WAAMMat programme. |
Collaborator Contribution | Direct funding, materials and application requirements. |
Impact | Two journal papers, international collaborations |
Start Year | 2014 |
Title | Additive manufacture |
Description | Method of producing a 3D article by additive manufacture, comprising the steps of; i) forming a meltpool in an already-existing part of the article and moving the meltpool relative thereto; ii) feeding a directed feedstock (which may be a wire or tape) into the moving meltpool to deposit and fuse a layer of material on the already-existing part; and iii) repeating the forming and moving and feeding steps to build up successive layers of material, and thereby produce the 3D article, wherein, in performance of the forming and moving step; a) a first energy source (which may be a plasma transferred arc) is directed onto the already-existing part, the first energy source impinging at a first region which moves with and leads the meltpool, whereby the first energy source initiates the formation of the meltpool and b) a second energy source (which may be one or more lasers) is directed onto the already-existing part, the second energy source impinging at a second region which moves with and follows the first region, whereby the second energy source grows the lateral width of the meltpool before the feedstock is fed therein. A third energy source may be used to melt the feedstock. |
IP Reference | GB2569673 |
Protection | Patent granted |
Year Protection Granted | 2019 |
Licensed | No |
Impact | None so far |
Title | Processes for additive manufacture and surface cladding |
Description | A gas metal arc welding device can have one or more consumable electrodes 4 delivered to the melt pool at a hot material feed rate; and a non-electrode, supplementary feedstock 10 delivered at a cold material feed rate. A 3D article 6 and/or cladding overlayer can be made; whereby the ratio of the hot material feed rate to the cold material feed rate can be varied during manufacture; e.g., based on sensed temperatures; or in relation to the travel speed of the meltpool. The device may have a gas shroud 3, contact tip 2, arc 5, and controller 11. The deposited bead shape and material microstructure can be kept constant as the article 6 temperature changes. The cold feed 10 may be preheated. High resolution exterior parts of an article can be built slowly while rougher core parts are filled more quickly, in a 'skin and core' approach (figure 7). |
IP Reference | GB2601784 |
Protection | Patent / Patent application |
Year Protection Granted | 2022 |
Licensed | Yes |
Impact | This process is currently being implemented into the commercial RoboWAAM system manufactured by WAAM3D |
Title | WAAMCost |
Description | Creation of WAAMCost, a cost estimation tool for industry partners to estimate the cost of a component made by WAAM and machining from solid, for titanium, four aluminium alloys, and Inconel 718. Also enables studies of the effects of higher build rates on cost benefit for different types of applications. |
Type Of Technology | Software |
Year Produced | 2016 |
Impact | Generation of much higher level of interest in WAAM technology and therefore industrial partners joining the WAAMMat programme. |
Company Name | WAAM3D |
Description | WAAM3D manufactures specialist components using wire-based directed-energy-deposition additive-manufacturing (WAAM). |
Year Established | 2018 |
Impact | WAAM3D has secured £1.5 Million of investment from an overseas investor and is now recruiting to 12 staff (5 so far). It has received it first orders for systems and wire valuing nearly £2 Million already. It has also secured research contract for €300k. The company is currently securing its own premises. |
Website | http://www.waam3d.com |
Description | Bekaert visit |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Lab visit and presentations |
Year(s) Of Engagement Activity | 2017 |
Description | Belgian welding society talk |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Keynote lecture at Belgian Welding Society 75 year celebration workshop |
Year(s) Of Engagement Activity | 2017 |
Description | ICWAM talk |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Plenary lecture at ICWAM 17 conference Metz |
Year(s) Of Engagement Activity | 2017 |
Description | India visit |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Visit to various industrial companies and research institutions in India (IIT Bombay, IIT Indore and CMTI Bangalore) - presentations given and applications of the technology discussed |
Year(s) Of Engagement Activity | 2016 |
Description | NIIAM opening |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Keynote presentation at formal opening of the National Innovation Institute for Additve Manufacture (NIIAM) in Xian China |
Year(s) Of Engagement Activity | 2017 |
Description | Plenary lecture at AMS Pressure and Pipe Welding Conference Hawaii |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Plenary lecture at AMS Pressure and Pipe Welding Conference Hawaii July 2017 |
Year(s) Of Engagement Activity | 2017 |
Description | Prof eng article |
Form Of Engagement Activity | A press release, press conference or response to a media enquiry/interview |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Article in Professional Engineering, February 2014, "3D printing takes off" |
Year(s) Of Engagement Activity | 2014 |
Description | Twitter account |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Public/other audiences |
Results and Impact | WAAMMat twitter account |
Year(s) Of Engagement Activity | 2015 |
Description | Video |
Form Of Engagement Activity | A press release, press conference or response to a media enquiry/interview |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Educational video filmed for The Manufacturer |
Year(s) Of Engagement Activity | 2015 |
Description | WAAM website |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | WAAMMat website |
Year(s) Of Engagement Activity | 2016 |
Description | Youtube |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Public/other audiences |
Results and Impact | 2process videos uploaded on youtube |
Year(s) Of Engagement Activity | 2015 |