High Deposition Rate Additive Manufacture of Complex Metal Parts (HiDepAM)

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.

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.