INLADE

Integrated numerical modelling of laser additive processes

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 Obiettivo del progetto (Objective)

'The processes of laser cladding, deposition and surface alloying are increasingly used in modern manufacturing as surface enhancement, rapid manufacturing, tooling and repair processes. In the simplest terms, they are based on blowing a powder stream into a moving, laser-induced melt pool. Modelling of them is difficult as they are characterised by multiple phase changes and mass and heat flow patterns. This project will link the Laser Processing Research Centre at The University of Manchester, which is one of the largest laser groups in the UK with expertise in experimental investigation and analytical modelling of these processes, with ESI GmbH based in Germany, a commercial engineering simulation and software development group with headquarters in Paris, France and with expertise in many areas of numerical engineering and thermodynamic simulation. Its aim is to develop integrated software packages to simulate all stages of the processes, including powder conveyance, powder dispersion in the melt pool, melt pool dynamics and track formation and heat flow and stress formation in the substrate. The project is 4-years in length and involves close cooperation for selection of submodels (modelling methodology), coding, sub-models testing, selection of additional process investigations where necessary etc. Additional personnel to aid dialogue and exchange of ideas will be used at stages of the project. The developed models and software packages will aid the increasing number of users of these processes, especially the aerospace industries who demand tight control of them. The models proposed also represent academic advances in this field and can be further developed for microstructure simulation beyond this project.'

Introduzione (Teaser)

Additive laser manufacturing is a process where complex geometrical shapes can be built up in layers. A comprehensive model of the process using desktop computers will improve reliability and open up new markets.

Descrizione progetto (Article)

Additive manufacturing eliminates the need for moulds and dies, thereby reducing material waste occurring from post-processing and thereby minimises associated time and costs. The Multiple layer laser direct metal deposition (MLLDMD) process is an additive laser manufacturing technique used to make metal components from powders or add layers to existing ones.

Despite great potential, the unpredictability of additive manufacturing processes often result in products with low-quality finish, internal defects and high residual stresses. This limits their use in sectors such as the aerospace industry that have very tight tolerances and strict certification procedures. Researchers hope to overcome these limitations through the development of a new comprehensive process model on a desktop computer within the scope of the project 'Integrated numerical modelling of laser additive processes' (INLADE), to attract new business.

The MLLDMD process relies on powder spraying from a nozzle into a moving, laser-induced melt pool that solidifies to form the component or the surface layer. It is a very complex process involving multiple phase changes from the powder to the melt to solidification, with varying heat and mass fluxes.

INLADE produced the first published comprehensive model on a desktop computer that treated the complete process from inside the deposition nozzle to the final deposit. Researchers managed to seamlessly integrate different FORTRAN subroutines describing the individual processes. Experimental results on steel parts enabled verification of model performance.

The model can accurately simulate part geometry using initial process parameters through successful calculation of residual stresses and phase distributions. Intensive design work ensured efficient utilisation of computer resources and parallel processing for implementation on a desktop computer.

Industrial and academic conferences and workshops should ensure that further innovation and subsequent commercialisation will not be far behind. With the powerful modelling tool by INLADE in their hands, manufacturers will be able to reliably deliver superior parts to the aerospace sector. Opening new markets for additive laser manufacturing applications will enhance the competitiveness of the manufacturing sector that forms an important pillar of the EU economy.