High-performance process for the additive manufacturing of large vehicle components
High-performance process for the additive manufacturing of large vehicle components
The GEPROBA waDED process: producing complex geometries that are almost impossible to achieve using conventional processes such as casting or milling. Image: LKR
By developing new high-performance torches, adapted power sources and innovative special wires, material build-up rates are to be increased to up to 15 kg/h for aluminium and 20 kg/h for steel and copper. This represents an important step towards making the production of large components more efficient and economical.
The GEPROBA research project (which stands for “Increased productivity through optimised torch technology and additional wires for waDED”) led by the LKR Leichtmetallkompetenzzentrum Ranshofen (“Light Metals Technologies Competence Unit, Ranshofen”) of the AIT Austrian Institute of Technology is taking additive manufacturing a decisive step forward. The aim is to make the Wire-arc Directed Energy Deposition (waDED) process more efficient and sustainable for the production of large and complex vehicle components. For the heavy vehicle industry in particular, this technology opens up new possibilities in the production of components made from aluminium, steel and copper. According to the LKR, the waDED process combines the flexibility of additive manufacturing processes with the accessibility of proven industrial technologies. The use of standardised welding sources and industrial robots enables easy implementation in existing production environments. However, GEPROBA is going one step further: by developing new high-performance torches, adapted power sources and innovative special wires, material build-up rates are to be increased to up to 15 kg/h for aluminium and 20 kg/h for steel and copper. For the LKR, this is an important step towards making the production of large components more efficient and economical.
Manufacturing large components in a process-oriented manner with optimised topology
In the project, the optimised process is being tested on components for lorry trailers, electric motors and battery systems. The design phase is intended to ensure that these components can be manufactured in a process-oriented and topology-optimised manner. According to the LKR, this will allow for the production of complex geometries that are almost impossible to achieve using conventional processes such as casting or milling, which would also require significantly higher material consumption. In addition, a new workflow for waDED-specific topology optimisations is being developed to support the resource-saving production of the future. Complex demonstrators such as crash boxes and wheel rims have already been successfully manufactured in previous projects, as the LKR reports. With GEPROBA, this expertise is now being extended to other materials such as steel and copper, paving the way for broader industrial use. Source: LKR