Additive manufacturing in fabrication of large-scale lightweight structures

Important results from the project

The project aimed to develop a new concept for controlling additive manufacturing with laser and metal wire that enables the use of the AM method for crack-sensitive nickel alloys. The goals of the project were to achieve a high deposition rate and a crack-free material. The high deposition rate, made possible by Procada´s control concept, was demonstrated by a doubling of the deposition rate while maintaining stability. The crack-free material was demonstrated by stabilizing a previously unstable but crack-free parameter set.

Expected long term effects

The project focused on AM for large-scale components where good material integrity is seen as an enabler for broad use of generative design for lightweight products. The project has demonstrated good conditions for the manufacture of lightweight constructions in crack-sensitive materials using AM with laser and wire. Procada´s feedback control concept proved to be able to enable drastic increases in deposition rate while also enabling the use of previously unstable, but materially advantageous, process parameters.

Approach and implementation

The project´s main activities consisted of deposition experiments using Procada´s new control system and following material evaluation. The control system was evaluated in University West´s equipment through a sensitivity analysis against process variations. The result showed major improvement in robustness when using unstable (but metallurgically sound) parameters compared to conventional control systems. The next phase was to build material for test samples. These were cut up for metallographic evaluation and the analysis showed that a crack-free material was obtained.