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

**AdCast** 是一种激进的方法，可在两个关键领域减少高价值金属铸造产品的损失：铸造厂和现场。5%的铸件因缺陷而无法修复而报废，每年在全球产生数千吨废料。另外20%的缺陷铸件需要重新加热，并使用大量气体进行手动修复。为了实现这一改变游戏规则的进步，我们首次将三种技术结合在一起：** 定向能量沉积（DED）技术，在具有挑战性的高铬铸造基材上进行存款金属修复。**用于DED的金属丝原料，** 针对高铬含量白色铸铁件的修复进行了优化，这些铸铁件非常坚硬且难以修复。**人工智能辅助 * 软件。** 3D扫描将缺陷与标称CAD形状进行比较，并自动生成3D添加焊接路径，并校准到目标铸件位置。这种 ** 添加修复（AdR）** 方法将改变高规格铸件结构的修复（在铸造厂和现场）进行高风险的资源密集型操作 **，需要数天 ** 的烘箱加热和手工劳动，结果不一，财务可行性差，智能化、自我改进和高效的操作 ** 耗时数小时 **，无需预热。行业专家的存在是关键：* 伟尔矿业，一家全球制造公司，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拥有基于AI的CNC仿真和分析工具，适用于DED操作，可用于提供快速维修校准和自动化维修程序。MTC拥有先进的基于激光的AM系统，具有实时监控和检测技能，可优化质量和速度。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公司受益。

**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.