High Deposition Rate Additive Manufacture of Complex Metal Parts (HiDepAM)

加法制造(AM)是一个逐层制造部件的过程。以一种简化的方式，它可以被描述为组件的3D打印。这项技术之所以重要，是因为它在逻辑和概念上都非常简单，具有重大好处。例如，它将大大减少材料和能源的使用以及飞机等结构的制造。降低材料损耗是一个重要的问题，因为目前航空航天部门从规则形状的结构中加工出复杂的形状。这导致了大量的浪费和非常高的购买与飞行比率，即与飞机上的材料相比，需要购买大量的材料。AM能够创建复杂的组件体系结构，这将补充软件设计技术的进步。因此，AM技术被确定为未来制造业的变革性技术也就不足为奇了。该项目正在解决AM技术在制造飞机等应用中实施的两个主要障碍。这些都是非常高的工艺成本和正在沉积的材料的性能。在目前的方案中，多学科小组寻求调查克服障碍的AM过程的发展。这包括一种新的AM工艺，基于使用激光的组合方式，一种新的添加材料的方法。我们还在开发一种与AM工艺配套的新工艺，该工艺可以转换材料的性能，使其与目前飞机上使用的材料相似。这种新工艺使用像轧制这样的技术将冷加工引入金属中；这在微观层面上改变了材料的结构。最后，将评估复杂形状、错位(不是垂直向下)和多轴沉积和集成加工的制造，以从单一工艺生产近净形状。该研究方案还将研究利用空间分辨声波光谱技术开发一种创新的、非破坏性的微结构在线过程控制方法的可行性。该联合体是精心组建的，合作伙伴之间拥有互补的知识库，因此可以在项目跨度内取得重大进展。这一跨洲活动将通过定期访问、基于网络的讨论和调查员交流方案，帮助利用默示知识库。该项目有望解决AM技术中确定的主要问题，使其早日在工业中应用。

Additive manufacturing (AM) is a process of building a component layer by layer. In a simplified manner, it can be described as 3D printing of a component. The technology is important because it is logistically and conceptually extremely simple with major benefits. For example it would lead to significantly reduced material and energy use and manufacture of structures such as aircraft. Lowering of material wastage is an important issue as presently the aerospace sector machines out complex shapes from regular shaped structures. This causes significant wastage and a very high buy to fly ratio, i.e. A large amount of material needs to be purchased compared to that which goes on the aircraft. AM is able to create complex component architectures which would supplement the advancement in soft design technology. Therefore, it is no wonder that AM technique has been identified as one of the transformational technology for the future manufacturing sector. This project is tackling two major barriers to implementation of AM technology for applications such as making aircraft. These are the very high cost of the process and the properties of the material that is being deposited. In the present programme the multi-disciplinary team seeks to investigate the development of AM processes that are overcome the barriers. This includes a new AM process based around the use of the laser combined ways a new method of adding material. We are also developing a new process to go with the AM process which transforms the properties of the material so that it is similar to the material currently used on aircraft. This new process uses techniques like rolling to introduce cold work into the metal; this changes the structure of the material at the microscopic level. Finally manufacturing of complex shapes, out of position (not vertical down) and multi-axes deposition and integrated machining will be evaluated for production of near net shape from a single process. The research programme would also study the feasibility of developing an innovative and non-destructive way of online process control of microstructure by Spatially Resolved Acoustic Spectroscopy (SRAS) technique. The consortium is carefully formed with complimentary knowledge base between the partners so that a significant progression can be made within the project span. This cross continental activity will help in leveraging the tacit knowledge base through regular visits; web based discussions and investigator exchange programme. The project is expected to solve the major issues identified in AM Technology, leading to its early application in industry.