CHAMPP - Casting Hybrid Additive Manufacturing Parts Production

**项目愿景**根据市场和市场网站的数据，2019年电动汽车(EVS)的全球销量达到约330万辆(市值约为1230亿GB-联合市场研究)。预计到2030年，这一数字将达到约2700万台/年。因此，汽车行业必须适应与重型电池相关的挑战，以及向模块化发展的转变，这是拼车和临时拥有等新商业模式所必需的。添加剂制造(AM)具有为设计师和制造商提供解决方案的潜力，但目前受到速度、最大部件尺寸和相对较高的每部件成本(超过铸造成本的两倍)的限制。**创新**Casting-Hybrid-Additive-Manufacturing-Parts-Production计划将应对这些挑战，开发创新的新混合工艺。通过将AM(设计灵活性)与低单件成本铸造相结合，CHAMPP将能够获得AM(设计灵活性)的好处。汽车制造商将能够在多个车型/OEM上铸造主要部件，然后使用AM按所需数量为特定变种定制这些部件，这些部件只能进行3D打印。引入AM还将支持快速和更具成本效益的原型和设计迭代。这一领域的最新技术完全基于研究，主要集中在钢材上。然而，钢铁的低成本，以及设想的复杂供应链和/或昂贵的新机器，阻碍了大规模混合动力进入主流。铝的杂化研究一直受到传统铸造/锻造合金的限制，在AM中使用时，机械性能较差。同样，目前的铝合金AM粉末不适合汽车应用，因为它们的机械性能较差，存在许多缺陷。这个Smart项目将解决这个问题，在该财团先前的合金和混杂研究的基础上，开发和测试更适合未来汽车AM和混杂需求的新铝合金(S)。**该财团**CHAMPP财团创造了一批关键的技术和市场专业知识：*合金：合金设计和AM专家。*布鲁内尔大学伦敦的BCAST：金属铸造和加工专家。*Autotech：Gestamp的研发部门，世界一流的全球汽车零部件制造商和一级供应商。

**Vision for the project**According to MarketsAndMarkets.com, in 2019 global sales of Electric Vehicles (EVs) reached ~3.3million units (a ~£123billion market value - Allied Market Research). This is projected to reach ~27m units/annum by 2030\. The automotive industry must therefore adapt to the challenges associated with heavy batteries and the move towards modularity that is required for new business models such as ride-shares and temporary ownership.Additive Manufacturing (AM) has the potential to offer designers and manufacturers solutions, but is currently limited by speed, max part size and a relatively high cost-per-part (over twice the cost of casting).**Innovation**The Casting-Hybrid-Additive-Manufacturing-Parts-Production (CHAMPP) programme will address these challenges to develop an innovative new hybridisation process. CHAMPP will enable access to the benefits of AM (design flexibility) by combining it with the low cost-per-part of casting. Automotive manufacturers will be able to cast the main components across multiple models/OEMs, then use AM to customise those parts for specific variants at the volumes required, with parts that can only be 3D printed. Introducing AM will also support rapid and more cost-effective prototyping and design iteration.The state-of-art in this domain is entirely research-based and has mostly focussed on steel. However, steel's low cost and the complex supply chains and/or expensive new machines envisaged have blocked large-scale hybridisation reaching the mainstream. Research on hybridisation using aluminium has been limited by traditional cast/wrought alloys which, when used in in AM, give poor mechanical performance. Similarly, current aluminium alloy AM powders are not suited for automotive applications as they have poorer mechanical properties with many defects.It is this problem this Smart project will address, building on the consortium's prior alloy and hybridisation research to develop and test new aluminium alloy(s) better suited to future automotive AM and hybridisation needs.**The consortium**The CHAMPP consortium creates a critical mass of technical and market expertise:* Alloyed: Alloy-design and AM specialists.* Brunel University London's BCAST: Metal casting and processing experts.* Autotech: An R&D arm of Gestamp, a world-class global manufacturer and tier\#1 supplier of automotive parts.