Metal deposition through additive manufacturing methods
| Reference number | |
| Coordinator | Högskolan Väst - Institutionen för ingenjörsvetenskap |
| Funding from Vinnova | SEK 4 799 221 |
| Project duration | September 2019 - July 2022 |
| Status | Completed |
| Venture | The strategic innovation programme SIP LIGHTer |
| Call | Lightweight technology - feasibility studies, and research and innovation projects spring 2019 |
Important results from the project
Many samples were produced using the experimental design of aluminum alloys 5183, 4043, 2319, and 5356. Some of the samples produced were subjected to tensile and high-cycle fatigue regarding the influence of surface finish and texture. In addition to the mechanical tests performed by SWERIM, extensive metallographic work was carried out, and demonstrators were produced. Demonstrators were manufactured by University West, BAE Systems, and Hydro and then successfully tested under high forces and pressures to verify their performance in real-world conditions.
Expected long term effects
The WAAM process has within the METTHRAM project successfully been applied to cheaper materials such as aluminium alloys 5183, 4043, 2319, and 5356. With WAAM, traditional manufacturing i.e forging has been significantly simplified, geometries optimized, component manufacturing times significantly reduced, and component weight reduced (25%) which in turn has a great impact on the final cost. The mechanical performance and its associated microstructure of the produced demonstrators are better compared to existing components produced via the traditional manufacturing route.
Approach and implementation
Robotic metal deposition wire (rMDw) was introduced to the partners. The selection, design, and testing of the demonstrator were carried out in close collaboration where the implementation strategy of the developed sub-components and demonstrators involved manufacturing and evaluation through mechanical testing and material characterization. An optimal selection of rMDw parameters was made based on deposition rate, surface quality, substrate corrosion potential, mechanical properties, ease of fabrication, preheat temperature, and microstructure.