CHAMPP - Casting Hybrid Additive Manufacturing Parts Production

**项目愿景**根据MarketsAndMarkets.com的数据，2019年全球电动汽车（ev）销量达到约330万辆（市值约1230亿英镑- Allied market Research）。预计到2030年，这一数字将达到2700万辆/年。因此，汽车行业必须适应与重型电池相关的挑战，以及向拼车和临时所有权等新商业模式所需的模块化转变。增材制造（AM）有潜力为设计师和制造商提供解决方案，但目前受到速度、最大零件尺寸和相对较高的每个零件成本（超过铸造成本的两倍）的限制。**创新**铸造-混合-增材制造-零件生产（CHAMPP）项目将解决这些挑战，开发一种创新的混合工艺。CHAMPP将通过将AM（设计灵活性）与铸件的低成本相结合，使其能够获得AM（设计灵活性）的好处。汽车制造商将能够在多个车型/原始设备制造商中铸造主要部件，然后使用增材制造根据所需的数量定制这些部件，而这些部件只能通过3D打印。引入增材制造还将支持快速和更具成本效益的原型设计和设计迭代。这一领域的最新技术完全是基于研究的，而且主要集中在钢铁上。然而，钢铁的低成本、复杂的供应链和/或昂贵的新机器阻碍了大规模混合化成为主流。传统的铸造/变形合金在增材制造中使用时，力学性能较差，限制了铝复合材料的研究。同样，目前的铝合金增材制造粉末也不适合汽车应用，因为它们具有较差的机械性能和许多缺陷。这个Smart项目将解决这个问题，在该联盟先前的合金和混合研究的基础上，开发和测试更适合未来汽车增材制造和混合需求的新型铝合金。**联盟** CHAMPP联盟创造了技术和市场专业知识的临界质量：*合金：合金设计和AM专家。*伦敦布鲁内尔大学BCAST：金属铸造和加工专家。*汽车技术：海斯坦普的研发部门，海斯坦普是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.