Additive Manufacturing for Repair and Re-use of Castings - AdCast

**AdCast**是一种激进的方法，以减少两个关键领域的高价值金属铸造产品的损失：在铸造和在现场。5%的铸件由于缺陷而无法修复而报废，全球每年产生数千吨废料。另外20%有缺陷的铸件需要重新加热，并使用大量气体手工修复。为了实现这一改变游戏规则的进步，三种技术将首次结合在一起：**定向能量沉积** (DED)在具有挑战性的高铬铸造基板上沉积金属修复。**用于DED的金属丝原料，**针对高铬含量白口铁铸件的修复进行了优化，出了名的硬且难以修复。* * AI-assisted * * * *软件。** 3D扫描将缺陷与标称CAD形状进行比较，并自动生成3D增材焊接路径并校准到目标铸造位置。这种**添加剂修复(AdR)**方法将改变高规格铸件结构的修复（在铸造厂和现场），从一个需要几天的烤箱加热和体力劳动，结果不稳定，财务可行性差的高风险，资源密集型操作**，到一个智能，自我改进和高效的操作**，只需几个小时**，不需要预热。行业专家的参与是关键：* Weir Minerals是一家全球性制造公司，致力于通过减少铸造废料和提供维修/翻新服务来提高可持续性和资源效率。* AiBuild具有基于人工智能的CNC仿真和分析工具，适用于DED操作，将用于提供快速修复校准和自动修复程序。* MTC拥有先进的基于激光的AM系统，具有实时监控和检查技能，以优化质量和速度。通过在全球范围内提供翻新和维修电池的技术，AdCast将显著影响全球资源效率，并通过出口世界领先的产品和服务使英国plc受益。

**AdCast** is a radical approach to reduce the loss of high-value metal-cast products in two key areas: in the foundry and in the field. 5% of castings are scrapped as unrepairable, due to defects, generating thousands of tonnes scrap globally per year. A further 20% of defective castings are re-heated and manually repaired using large amounts of gas.To achieve this game-changing advance three technologies will be combined for the first time:**Directed Energy Deposition** (DED) to deposit metal repairs on challenging high-chrome cast substrates.**Metal wire feedstock for DED,** optimised for the repair of high chrome-content white iron castings, notoriously hard and difficult to repair.**AI-assisted** **software.** 3D scanning will compare defect to nominal CAD shape and automatically generate the 3D additive weld path and calibrate to the target casting location.This **Additive Repair (AdR)** approach will change the repair of high-specification cast structures (in the foundry and in the field) from a risky, resource-intensive operation **taking days** of oven heating and manual labour with variable results and poor financial viability, to an intelligent, self-improving and efficient operation **taking hours**, requiring no pre-heating.The presence of industry experts is key:* Weir Minerals, a global manufacturing company, with drive to improve sustainability and resource efficiency by reducing foundry scrap and offering repair/refurbishment services.* AiBuild has AI-based CNC simulation and analysis tools adapted to DED operations that will be leveraged to provide rapid repair calibration and automated repair routines.* MTC has advanced laser-based AM systems with skills in real-time monitoring and inspection to optimise quality and speed.By providing the technology for refurbishment and repair cells globally, AdCast will significantly impact global resource efficiency and benefit UK plc by the export of a world-leading products and services.