The BLEND project will test and validate a manufacturing system for combining two different metals into a single part. The resulting part will be made the two metals blended together with computer controlled proportions at any given point. This continuous change of chemistry along the length of the part will result in corresponding unique performance properties along its length. This will enable the part operate in a highly demanding use environment, yet without the complexity or weakness that are normally induced when joining two parts made of different metals together.
"Power Electronics, Machines and Drives (PEMD) are technologies that enable the control and delivery of electrical energy and includes propulsion in transportation, energy generation and distribution, industrial machines and robotics. They are used in supply chains, like conductors and semiconductors, converter/inverter systems, \[and\] novel electric motor topologies." (KTN, InnovateUK)
Efficient and effective thermal management of PEMD is evolving. Optimisation of thermal management products to match ever-higher power densities, whilst reducing weight and footprint, has created an urgent need for innovation in heatsink and cooling plate technology.
The increased power densities of electric vehicle (EV) batteries and high-power electronics have led to heat generation at rates beyond the ability to simply air-cool them. Just as many living organisms regulate their temperature by circulating blood throughout their bodies, the next step for thermal management in these high-performance products is to also circulate a cooling liquid. However, contrary to living organisms that biologically grow an interconnected network of blood vessels, manufacturing similar passages inside of parts is a significant engineering challenge. Current solutions, as operated by _PSL Assemblies Ltd_ (PSL), require combining multiple materials and many labour-intensive steps.
_TWI Ltd_ (TWI) has recently invented a new sub-surface machining technique called CoreFlow(TM). It reaches through the outer "skin" of a part to remove the inside "core" of it, all without removing the outer skin. This new solid-state process allows for the creation of sub-surface networks of channels to be created within solid metal parts directly, thus enabling smaller form-factor and lighter thermal management components. Furthermore, it is digitally driven allowing for the creation of customised sub-surface network sizes and patterns without the need for additional tooling. This approach has transformative potential for producing higher-performance thermal management solutions with elevated reliability.
**_The main drawback of this approach is that it relies on costly specialised manufacturing equipment._**
_Hybrid Manufacturing Technologies Ltd_ (HMT) modularises specialist processes into heads that are useable on mainstream machine tools (the most foundational metalworking tool in the manufacturing industry). In the _SubSurface_ project HMT will migrate the CoreFlow(TM) process invented by TWI into a highly accessible and cost-effective solution, retrofittable to existing CNC machines. This will allow the formation of sub-surface networks and external machining to be accomplished in one machine and drive competitiveness and performance to new heights. This will empower _PSL_ and associated UK industry unprecedented leadership in thermal management solutions to enable next-generation PEMD technologies and bespoke liquid-cooled products.
COVID-19 has caused significant disruption to many markets and has created a need for flexible and adaptable manufacturing methods that can offer significant economic advantages to cope with the disruption. Additive manufacturing (AM) is an obvious candidate that has already seen some industrial success especially in the aerospace, medical and power generation sectors due to its high process efficiency, low material wastage, and the ability to manufacture components or coatings with complex geometries and/or improved material properties.
The compact wire-feed head developed by HMT for wire laser metal deposition (w-LMD), a form of AM, has the potential to supersede both traditional subtractive manufacturing methods as well as current state-of-the-art AM processes. The head is capable of depositing material between 0.5 -- 4+kg/hr and was developed from standard w-LMD side-feed technology. However, its unique design allows for a more stable process with effective-omnidirectional deposition. The head is also very adaptable due to its compact size, where its laser - blown powder variant is globally leading in its design for ease of integration into machine tools though automated tool change system.
This project will develop and deploy an innovate approach for wire delivery in LMD to prove the commercial viability in a number of different industrial sectors. This will be achieved by applying the technology to a number of real-world industrial components to demonstrate added-value and market potential within the UK.
The key outputs from _FastWireAM_ are:
1\.**Demonstration of added-value** provided by the w-LMD head, including reduced production time and material waste, accelerating **market uptake** in a number of diverse sectors and applications to provide additional revenue streams for the partners.
2\.**Improved hardware and process** through performance mapping and parameter optimisation, ensuring a robust and reliable manufacturing method and quality required by industry.
The successful completion of this project will demonstrate and establish the commercial viability of this process. We expect that the technology will be offered as a manufacturing solution to both current and new customers and revenue streams, and retrofitted onto new and existing machine tools.
"Metal Additive Manufacturing (AM) is an emerging technology for rapid prototype manufacturing, benefitting aerospace and medical devices, as the immediate manufacturing of high-value, complex structured components is usually necessary in these industries. Hence, the structural integrity of printed structures is extremely important and should meet the specifications and high standards of the above industries. In several metal AM techniques, e.g. selective laser melting (SLM), electron beam additive manufacturing (EBAM) and wire arc additive manufacturing (WAAM), residual stresses and micro-cracks that occur during the manufacturing procedure can result in irreversible damage and structural failure of the object after its manufacturing. Repetitive faults which occur during manufacturing due to incorrect estimation of appropriate operating conditions of the printer should be eliminated, as any waste is undesirable and costly for a company.
The nature of some AM methods means that not all Non-Destructive Testing (NDT) techniques are effective in detecting residual stresses. Thermography, X-ray computed tomography (CT scan), or digital radiography are limited by the resolution of images (thermography), they are bulky and costly (up to £100k), are not suited to residual stress detection. Our solution, EM-ReSt, functions as an add-on to existing AM processes, comprising two sets of NDT techniques: Electromagnetic Acoustic Transducers (EMAT) and Eddy Current Testing. A crucial (and novel) extension of the proposed system is the incorporation of big data collection from the sensors and analysis through machine learning (ML) for estimating the likelihood of the AM techniques to introduce anomalies into the printed structures before the beginning of the manufacturing. A digital system that will estimate the potential and deficiencies of any AM technique for given structures will be developed and utilised for the establishment of a preliminary set of AM standards. Hence, more robust and reliable components will be printed and used.
EM-ReSt is fast (msecs/measurement and overall scanning time does not exceed a minute), reliable (90% PoD), non-destructive online monitoring of AM techniques, can achieve 15% reduction of faulty outputs with the use of 4 times more cost-effective monitoring system, has low profile sensing hardware with potential for EMAT and EC miniaturization. Our initial target markets are the global aerospace and automotive component manufacturing market. This project represents a clear technological innovation for the UK AM industry, and major growth opportunity for the SME supply chain consortium, which is forecast to generate revenues of £72.5M and 362 new jobs 5 years post-commercialisation."
There is a large emphasis across the tool and die (T&D) sector to develop new methods which reduce cost, improve life and functional performance. The European T&D market is estimated at 11 billion USD per year and the UK spends £130m on closed die forging and sheet metal dies alone. These industries are made up of a large number of SMEs and adopting new methods require significant investment. The approach will develop an additive manufacturing digital framework which has cross sector applicability in all re/manufacturing applications and can be integrated with existing legacy machine tools, providing an affordable solution. The potential benefits are; rapid T&D re/manufacture (hybrid single platform); circular economy approach; gain on material utilization; saving on machine time; saving on consumable costs; lead time reduction; reduced energy consumption; improved performance. TTL (lead), Advanced Forming Research Centre, Hybrid Manufacturing Technologies, Hexagon and ATS Global will collaborate to achieve this. Mills Forging will provide an end user demonstrator case that will provide them with opportunities to be more competitive and diversify into different markets (automotive and aerospace) and employ staff in highly skilled areas.
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
The 2G-HMS project builds on the success of the Innovate UK supported RECLAIM project which developed the World’s first Hybrid Manufacturing System (HMS) capable of seamless switching between additive manufacturing (laser cladding) and subtractive manufacturing (high speed milling) in a single machine using a novel docking system. Although the HMS approach is now being commercialised by HMT, a spin out from the RECLAIM project, with the support of other partners including the MTC further developments are urgently required. The partners in the project will increase the productivity and flexibility of the HMS approach, ensure improved part quality through process monitoring and control, extend the range of proven materials and demonstrate the efficacy of the system in applications from key end-use sectors. The developments in the 2G-HMS project will provide a step changes in process capability which will enable new markets to be explored which is essential for HMS to gain widespread acceptance and to ensure that the UK maintains a lead in this important technology
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.
Directed Energy Deposition Additive Manufacturing (AM), known as cladding, where a metal powder or wire feed is melted using electron/laser beam or electric arc, has significant advantages over powder bed fusion AM. Cladding offers very high deposition rates, material flexibility, and can be used in a hybrid approach, enabling complex features or different material to be deposited onto an existing component produced conventionally. In the ACCLAIM project Plasma Transfer Arc (PTA) cladding will be employed, offering excellent weld quality, low capital/running costs, very high deposition rates, material flexibility and minimal substrate interaction. 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.