Modelling of Sustainable AM Processes for Fabrication in Lightweight Solutions

Important results from the project

The project has evaluated simulation models of varying complexity for LPBF and heat treatment, incl. inherent strain and coupled thermomechanical analysis of geometries and component like geometries. Physical tests have been done for validation of temperature, damage development via NAW®, synchrotron X-ray and optical microscopy. The project has validated the ability to predict measured far-field temperature, residual stresses, and industrial technology maturity for future critical components.

Expected long term effects

The project contributes to increased technology maturity for LPBF through improved model development and simulation-driven optimization. This will enable robust production of critical components with high predictive accuracy regarding temperature history, residual stresses and defects. Continued competence building, new research collaborations and AI-assisted development are expected to strengthen competitiveness and contribute to sustainability and efficiency in the aerospace industry.

Approach and implementation

The project has worked with cases with test geometries and component-like demonstrators. FE analysis was performed with experimental studies to study the behavior of individual passages as well as damage development and residual stresses. Initially, the modeling work was adjusted down in favor of testing the in-situ method for damage detection with NAW®. The collaboration has worked well and there is a desire to continue with studies of temperature history and prediction of damage and failure.