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Fraunhofer lighthouse project "futureAM" expected to speed up
"additive manufacturing" by a factor ten
Scientists at the Fraunhofer Institute for Material and
Beam Technology IWS in Dresden have developed innovative methods enabling
more materials to be processed in additive manufacturing than ever before. For
example, additive manufacturing systems could facilitate better future aircraft
engines with lower fuel consumption.
However, engineers must first improve the current industrial 3D printers in such a way that these machines can also process very strong and extremely heat-resistant alloys. Here, the Dresden researchers rely on their profound experience with laser powder buildup
welding technologies and employ artificial intelligence (AI). They contribute
their profound materials expertise to the Fraunhofer joint project "futureAM".
The aim of the partners is to speed up additive manufacturing systems for
metal components by a factor ten and also to manage superalloys.
Fraunhofer IWS engineers have refined laser powder buildup welding over decades in
order to allow more materials to be applied in additive manufacturing. In this
procedure, a system feeds various filler powders into a process zone. There, a laser
melts the powder and deposits it on a workpiece surface. As a result, the desired part is
generated in a layer by layer process. "One of the advantages of this additive
procedure is that we can adapt the process very flexibly to the requirements of highperformance materials," explains Fraunhofer IWS project administrator Michael Müller.
In this way it is also possible, for example, to print nickel-based alloys that are difficult
to weld and process using traditional methods. However, this only works if the
temperature, powders, feed rate and other parameters are correct. "We have to adjust
all the set screws precisely," explains Michael Müller. "This is the only way we can find
the right recipe." Within the framework of the Fraunhofer lighthouse project
"futureAM - Next Generation Additive Manufacturing", IWS engineers are recording
numerous sensor data with very high sampling rates for this purpose. However, this
generates large amounts of data ("big data") that are difficult for people to
understand.
AI learns to decide
Nevertheless, Fraunhofer experts use advanced methods of "artificial intelligence" (AI)
and "machine learning", which are also researched under the catchword "Big Data" in
a working group led by Prof. Karol Kozak, Head of Image Processing and Data
Management at Fraunhofer IWS, to find hidden connections in these signal floods. For
example, special analysis algorithms link the measured sensor values with the institute's
powder database and evaluate further process parameters. Gradually, the machines
learn to make their own decisions. For example, they can determine for themselves
whether a slight rise in temperature in the welding process can be tolerated or whether
they have to take immediate countermeasures before the entire component ends up as
waste. "Industry is looking for ever more and ever different materials which are,
however, often difficult to process," emphasizes Prof. Frank Brückner, Business Unit
Manager Generation and Printing at Fraunhofer IWS.
Better aircraft engines in sight
The aircraft engines mentioned above are examples illustrating precisely this prospect:
they could work more efficiently and at higher temperatures if most materials were not
already failing at temperatures of around 1200 degrees. Admittedly, there are materials
that can withstand such high temperatures, but they are very cost-intensive and
difficult to process using traditional methods. Additive manufacturing is intended to
solve this dilemma. Moreover, it could help to achieve a more cost-effective design:
"Using laser powder buildup welding, we can feed different powders into the process
zone simultaneously or successively with precisely adjustable feed rates," explains
Michael Müller. Designing an entire component out of a singular material is not very
effective since the component is not exposed to the same heat at all points."
Preferably, the expensive, highly resistant material should only be used where it gets
really hot," says Michael Müller. "In other areas, a less expensive material will be
sufficient." This is precisely what can be achieved with additive manufacturing systems
– once they have learned to process the required superalloy. "The next step is to
combine various high-performance materials within a single component," announces
project administrator Müller. In the "futureAM" joint project, the IWS and five other
Fraunhofer Institutes are pooling this technology and further expertise to push additive
manufacturing to a new level. By summer 2020, they want to integrate all their
expertise into the additive manufacturing process chain and demonstrate it on realistic
components.
Background information: This is "Additive manufacturing"
Additive manufacturing (AM) is regarded as a key technology for "Industrie 4.0". It is
designed to combine the advantages of mass production and manufacturing and even
to generate individual parts ("batch size 1") economically on an industrial scale. AM
machines can also freely create highly complex components that cannot be produced
using conventional milling and turning machines. These machines use principles similar
to those used by 3D printers in the creative and DIY scene: The desired component is
designed on the computer; subsequently this model is fed into the system, whereupon
a heating module or laser heats a plastic. From this material melt, the system generates
the designed part layer by layer. Compared to 3D printers for private use, AM systems
are far more efficient. They can, for example, process metals and ceramics as well as
plastics, usually use laser technology and work with extreme precision and more
complex CAD models.
"futureAM" takes additive manufacturing to a new Level
In November 2017, the Fraunhofer lighthouse project futureAM was launched with the
aim of accelerating additive manufacturing of metal components by at least a factor of
ten. The focus is on a holistic view of digital and physical added value from incoming
order to the finished metal 3D printing component. The central goal is a leap into a
new technology generation of additive manufacturing. Five other Fraunhofer institutes
are participating in this project under the leadership of the Fraunhofer ILT: IWS, IWU,
IAPT, IGD and IFAM.
Visit us at the exhibitions "LASER World of PHOTONICS" in hall A2, booth 431,
and "RAPID.TECH + FABCON 3.D" at AGENT-3D booth 2-435.
Business Unit Manager Additive Manufacturing and Printing
Prof. Dr. Frank Brückner
Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS
frank.brueckner@iws.fraunhofer.de
Phone +49 351 83391-3452
Winterbergstraße 28, 01277 Dresden
www.iws.fraunhofer.de
https://www.iws.fraunhofer.de/en/pressandmedia/press_releases/2019/presseinforma...
By means of laser powder build-up welding, components made of different materials can be integrally ...
© Fraunhofer IWS Dresden
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Fraunhofer IWS Dresden has developed a process and material database which stores all details of the ...
© Fraunhofer IWS Dresden
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