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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - OpenHybrid (Developing a novel hybrid AM approach which will offer unrivalled flexibility, part quality and productivity)

Teaser

Summary

The main aim of the OpenHybrid project is to overcome the technical and commercial barriers of current hybrid manufacturing systems to deliver a single manufacturing system, capable of producing large, complex and high value components without the need for materials handling or post-processing. The OpenHybrid project will develop an all in one hybrid additive and subtractive multi tool platform. It will utilise Directed Energy Deposition (DED) Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc. This approach has significant advantages over conventional powder bed fusion AM, in that cladding offers very high deposition rates, increased material flexibility, and can be in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the OpenHybrid project laser) cladding will be employed, offering excellent weld quality, low capital/running costs, very high. This route will also be applicable in offering a very effective repair technique.

The project will deliver the following benefits:
â€¢ At least a 25% reduction in time and cost with respect to current equipment and processes.
â€¢ A 15% increase in productivity for high-volume AM production
â€¢ Increased utilisation and reduced set-up times enabling the OpenHybrid system to better meet the needs of the customers (short delivery and customisation).
â€¢ A 20% reduction in inventory due to the single step process and greater flexibility.
â€¢ Reduction of work floor space by 40%.

In addition, the project will contribute to broader EC objectives by enabling localised manufacture within the EU, strengthening the current position of the EUâ€™s additive manufacturing value chain and contributing to new standards for hybrid manufacture.

These developments will unlock the potential of Hybrid AM place Europe in an unassailable lead in this key area of manufacturing technology. Novel techniques will be developed to reduce thermal stress and provide a robust inert gas environment to ensure material quality. Moreover, a machining process will be integrated to enable fully finished components to be produced. This route is not only applicable for new part production but could also offer a very effective repair technique.

OpenHybrid is an industry-led project involving major manufacturers in the target applications of large process and mining industries (WEIR), power generation (SIEMENS), automotive (FIAT). The supply chain of the project is represented by participants who supply of both large gantry systems (GÃ¼del) and CNC machine tools (GF), CAM software (BCT & PIC), tooling interfaces (HMT) and inspection equipment and services. The development is underpinned by three world-class research organisations (MTC, FHG-IPT and TWI). OpenHybrid addresses the major and growing problem for the AM sector of the cost, time and resource needed to finish parts post AM build, and thus directly addresses the post-processing part of the â€œPre- and post-processingâ€ topic. The complexity of AM parts makes them difficult to finish once completed, requiring specialist cutting tools and expensive fixtures to hold parts, and unfinished internal surfaces limit their fatigue durability. Machining in process in combination with novel stress relieving and in-process measurement significantly simplifies machining (shorter, more rigid cutting tools and simplified cutting strategies can be used). Cladding provides unrivalled material flexibility enabling material to be deposited in complex graded configurations, providing performance enhancement and design freedom. A key part of the project is to demonstrate the new process using demonstration parts, with novel design and material usage, provided by key industrial end-user participants. OpenHybrid will model the laser cladding deposition process, enabling the most effective deposition strategy to be devis

Work performed

Main achievements from M1 to M18 so far, include;

*Industrial requirements;

* Process tool development for OpenHybrid system;

* Material and Process parameter development;

* Process monitoring;

* Process modelling;

* CAD/CAM Interface development;

* Final Platform integration for large and small system;

Dissemination ;
The standard suite of early dissemination activities has been undertaken, including generation of project logo, press releases, leaflets, design and production of pop-up stands, creation of the project website and standard presentation slides.

The project has been promoted at European clustering/platform events (AM-Motion, EEFRA, AM platform and AMEF events throughout the course of 2017) and was presented in depth at the AM-Motion event held on the 17th November 2017 at EWF in Lisbon. In addition information on the project has been presented at public events including the TCT Exhibition at the NEC, Birmingham (25-27th September 2017) which was attended by over 10,000 people. In addition Openhybrid was presented at the Schweissen & Schneiden Fair (25-29th September, Dusseldorf.

In addition a meeting was held between the project partners from other hybrid AM projects (LASIMM, Kraken, Borealis etc.) at EWF on the 17th November. This proved very effective at identifying common issues which can be addressed collectively â€“ for example the sharing of information on markets for hybrid AM which can help with developing more robust business plans. Further workshops are planned.

Final results

Progress beyond the State of the art
Key Innovations in the OpenHybid project include;

- Process and Part monitoring:
- Development of worldâ€™s first wire feed dockable cladding head which can be interchanged seamlessly with other process tools without manual intervention or significant delay.
- In-process Stress Reliving.
- Simple to use CAM package which can be used to plan and execute both the machining and cladding steps within the hybrid DED AM process.

The OpenHybrid project supports the European 2020 grand societal challenges. Advances in additive manufacturing will contribute specifically to at least three out of five of the grand challenges, namely; supporting employment (75% if the 20-64 year olds to be employed), increasing investment in innovation (3% of the EUâ€™s GDP â€“ public and private combined to be invested in R&D & innovation), and reducing emissions through more energy efficient manufacturing (greenhouse gas emissions 20% less than 1990 and 20% increase in energy efficiency). In addition, the project supports the general objectives of the Factories of the Future PPP

OpenHybrid supports the sustainability agenda of reduce, reuse and recycle. The hybrid AM approach enables additive manufacturing processes that deliver near net shape technologies, inherently reducing the amount of material being used in the manufacture of a component. This will reduce the CO2 emissions associated with the extraction, synthesis and transportation of raw materials. The hybrid approach encourages component re-use creating new service offerings whereby components can be returned, re-machined and surface features to be reintroduced through the cladding process. The approach will also develop parts and components with inherently superior wear properties leading to longer lifetime.