The Additive Manufacturing Optimisation and Simulation (AMOS) project is working with a number of different AM processes and material so as to assess their use for repair. The objectives of the project are to:
- Study the process accuracy, repeatability, limitations and material integrity of a number of different direct energy deposition (DED) systems using a number of materials;
- Develop an effective system to generate the repair geometry;
- Develop accurate models to simulate the different deposition processes;
- Develop a repair process planning module;
- Develop a method to optimise component design for additive repair;
- Determine the data necessary for qualification of DED technologies for repair and remanufacture;
Within AMOS, the partners are carrying out fundamental research to understand the resultant material properties of a number of different DED processes for three different materials and investigating the accuracy and limitations of these. Common additive processes typically use either a numerical (CNC) or robotic controller, so to ensure broad applicability, both types of system will be studied. Repairs made using three aerospace alloys (Ti-6Al-4V, Inconel 718, and AerMet100) in both powder and wire form are being investigated. Depositions will be either using lasers or tungsten welding.
Partners are developing methods of effectively generating computer models of each unique defect which can be sent to the additive controller. In conjunction with new sensors developed by the Canadian partners and models of the processes, this will allow the repair trajectories and parameters to be generated for each repair, given the material and machine.
At the same time, partners will look at the overall component design process and optimise commonly damaged parts so that they are suitable for repair using DED processes.