MALT

Multilaser Additive Layer Manufacturing of Tiles

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 Obiettivo del progetto (Objective)

'Laser Additive Layer Manufacturing of tiles in various nickel superalloys has been demonstrated at TRL4. Considerable investment has been made in developing materials data for the processes of record employed on the current generation of equipment, however this equipment is for general purpose prototyping and is not capable of high volume, low cost production of flight parts.

The objective of this project is to develop a second generation machine suitable for low cost manufacture while maintaining process equivalence to the current processes of record. This will be achieved by the use of multiple lasers to address a larger build envelope and will otherwise be in line with the capability requirements stated in the topic call.

The Participants will first agree the requirements for the machine with the Topic Manager. From this a functional specification will be developed, embodying the essential design concepts to be realised. A test rig will be constructed and operated in order to explore methods for controlling the overlap areas between laser fields. An alpha system will be designed, constructed and tested in accordance with the functional specification and incorporating the learning from the test rig. A subsequent prototype machine, being a development of the alpha machine, will be designed built & tested prior to installation in a representative production environment. Validation testing will be performed on this machine in order to establish (1) metallurgical equivalence to the current processes of record, (2) accuracy, in particular in overlap regions, (3) system reliability and (4) cost of ownership metrics.'

Introduzione (Teaser)

3D printing is set to take off in aircraft combustor parts of thanks to an EU-funded project that is developing a next-generation laser additive manufacturing machine.

Descrizione progetto (Article)

Future legislation for large aircraft engine emissions requires a step change in combustor technology. A fundamental objective of lean burn is to combust fuel and air at cooler temperatures, resulting in lower oxides of nitrogen emissions. The most effective cooling designs are difficult to form conventionally and existing manufacturing methods require compromises that reduce performance or lifetime.

Laser additive layer manufacturing of tiles is capable of forming the required complex geometries in nickel superalloys. However, the equipment used is for general purpose prototyping of low volumes of rig parts and is not capable of high-volume, low-cost production for flight parts.

With EU funding of the project 'Multilaser additive layer manufacturing of tiles' (MALT), scientists are aspiring to produce a multilaser machine prototype that enables low-cost unit manufacture. The system will be scalable both in speed and the build envelope size for higher volumes and part size, without change in the laser melt characteristics. In addition, it should demonstrate equivalence to state-of-the-art additive manufacturing methods, while being cost competitive and flexible in its design.

Scientists aim to produce and operate a test rig to explore methods of controlling the overlap areas between the multiple laser fields. So far, they have developed a requirement document for the machine under development, outlining the performance requirements. These relate to the build envelope, dimensional accuracy, material properties, reliability and maintainability, and cost of ownership.

Based on this document, project partners have developed another document describing the validation testing that will be performed on the machine.

Scientists succeeded in designing a new process chamber incorporating four lasers and scanning systems. In addition, they used detailed computational fluid modelling to analyse the gas flow within the chamber. Software was developed to control the four lasers simultaneously, while various aspects of the system function were also tested. Simple test parts were manufactured and some preliminary material data was obtained.

MALT objectives are in line with the Advisory Council for Aviation Research and Innovation in Europe (ACARE), which has set ambitious targets for reducing harmful emissions.