WAVETAILOR - Modular laser sources for sustainable production of short personalized production series

Participantes:

JOANNEUM RESEARCH
PRIMA ADDITIVE
NLIGHT EUROPE
Z PRIME
DESTINUS SPAIN
AEROTECNIC METALLIC
MORPHICA
AUSTRIAN ENERGY AGENCY
TEMATYS
COVENTRY UNIVERSITY

Programa:

HORIZON-CL4-2023-TWIN-TRANSITION-01

Sectores:

Aeronáutico-Aeroespacial

Tecnologías:

Análisis de Datos

DED-LB

Visión Artificial

Objetivo

WAVETAILOR focuses on two industrial scenarios related to the complex multi-material component and assembly. The first one is Directed Energy Deposition of a multimaterial leading edge for a hypersonic hydrogen-driven airplane, while the second relates to the Powder Bed Fusion of complex multi-material assembly of a drone for urban delivery. The challenges in both cases are related with zero-defect manufacturing, sustainability and first-time-right manufacturing. WAVETAILOR aims to solve the high precision in complex material structure manufacturing, the disassembly, reuse and recycling of components, while reducing the environmental footprint of both manufacturing process and the components itself.

Solución

LORTEK focuses on developing digitalization and photonics strategies for DED-LB (Laser-based Directed Energy Deposition). It leads the work-package related to industrial scenario definition focusing on the hypersonic airplane use case. Specifically, LORTEK will integrate a new multiwavelength laser system and a processing head in the DED-LB cell able to use two wavelengths that, together with optimized deposition strategies, will lead to near-net-shapes preforms. Leading edge segments prototypes will be produced with the combination of at least 2 materials in the additive layers; copper alloys to take heat away from the skin panel, high-temperature nickel-based alloy to increase the durability and impact resistance of the leading-edge tip, and/or titanium alloys in reduced temperature zones to reduce weight. To ensure geometrical characteristics and tolerances, manufacturing strategies and post-processing considerations will be of utmost importance.