HIGH strength steel in LIGHTweight design with wire arc additive manufacturing

Purpose and goal

Project HIGHLIGHT will drastically reduce the weight of components, by 20 percent, using topology optimization and manufacturing with WAAM in high-strength steel. The manufacturing method enable reduced material usage, i.e. the same component will require less material with maintained or improved mechanical properties.

Expected effects and result

The additive manufacturing method WAAM creates many new variable design possibilities, as well as weight and cost savings in high-strength steels. The project is expected to create a weight reduction of 20% for selected demonstrators. This weight reduction benefits both vehicle solutions with combustion engines as well as more sustainable concepts in electromobility. The project results will lead to significantly increased competitiveness within Swedish lightweight technology from a sustainability perspective.

Planned approach and implementation

Focus will be on topology optimization. It is a mathematical tool used in construction work to optimize the macro or micro structure of an object. This is done with the primary intention of minimizing material usage as well as reducing weight without affecting the strength of the object. When an optimized structure of the object has been produced, the object will be manufactured with WAAM. In order to achieve the desired material properties in the WAAM- object, extensive process optimization will be perfomed. Finally, a demonstrator will be manufactured and acts as a proof of concept.