Additive manufacturing optimization and simulation platform for repairing and re-manufacturing of aerospace components

该研究项目是加拿大和欧洲的合作项目。它侧重于几个关键的直接能量沉积（DED）增材制造（AM）工艺，这些工艺具有很大的潜力，可用作涡轮机叶片和起落架等航空航天部件的成本效益和高效维修和再制造工艺。该项目旨在进行基础研究，以了解材料的完整性，通过选择DED AM工艺，这些沉积工艺的准确性和局限性，有效的缺陷几何映射和生成方法，以及自动化和混合DED和沉积后加工策略。该项目旨在通过精确的DED过程模拟和新颖的多学科设计优化（MDO）方法将维修和再制造策略与设计联系起来，以最终减少航空航天部件在设计阶段的弱点并延长其生命周期。将对基于粉末和基于线的DED系统进行调查，以建立全面的比较研究。通过这项全面的比较研究收集的数据将对该项目的原始设备制造商（即GKN，PWC和HDI）了解这些DED系统的利弊非常有价值，并将帮助他们选择合适的维修和再制造策略。在这项研究中进行的测试也是非常有益的中小企业在这个项目（即Liburdi，AV&R，DPS），以验证他们现有的维修系统和技术。常见的DED工艺由CNC控制器或机器人控制器控制，这取决于携带沉积喷嘴系统的机器的类型。在拟议的研究中，CNC控制和机器人控制的DED系统将被研究。在本研究中，有三种航空航天合金要研究：Ti-6Al-4V，Inconel 718和300 M合金钢。研究团队是多学科的，在专业知识和研究设施方面具有互补性。加拿大研究小组包括麦吉尔大学和渥太华大学的学者。欧洲研究团队包括来自法国南特中央理工学院和英国谢菲尔德大学的学者。

This research project is a Canada and European collaborative project. It focuses on several key Direct Energy Deposition (DED) Additive Manufacturing (AM) processes that have great potential to be used as cost-effective and efficient repairing and re-manufacturing processes for aerospace components such as turbine blades and landing gears. This project aims to conduct fundamental research to understand the material integrity through chosen DED AM processes, the accuracy and limitations of these deposition processes, effective defect geometry mapping and generation methods, and automated and hybrid DED and post-deposition machining strategies. This project intends to connect repair and re-manufacturing strategies with design through accurate DED process simulation and novel multi-disciplinary design optimisation (MDO) methods to ultimately reduce the weakness of aerospace component at design stage and prolong their the lifecycles. Both powder-based and wire-based DED systems will be investigated to establish an across-the-board comparative study. The data collected through this comprehensive comparative study will be extremely valuable for the OEMs of this project (i.e. GKN, PWC, and HDI) to understand the pros and cons of these DED systems and will help them to select suitable repair and re-manufacturing strategies. The tests conducted in this research are also extremely beneficial for the SMEs in this project (i.e. Liburdi, AV&R, DPS) to validate their existing repairing systems and techniques. Common DED processes are controlled either by a CNC controller or a robotic controller depending on the type of machine that carries the deposition nozzle system. In the proposed research, both CNC controlled and robotic controlled DED systems are going to be studied. There are three aerospace alloys to be investigated in this research: Ti-6Al-4V, Inconel 718, and 300M alloy steel. The research team is multidisciplinary and complementary in expertise and research facilities. The Canadian research team includes academics from McGill University and University of Ottawa. The European research team includes academics from Ecole Centrale de Nantes in France and University of Sheffield in UK.