Approach

 

The IMProVe technology project consists of three interlinked sub-projects:

 

 

Materials and processes

Steels (powder bed method: EBM, LBM)	Ceramics (Binder-Jetting)		Ceramics (LCM-process)		Fe-Ni-alloy (powder bed method: EBM, LBM)
Rust- and acid-resistant Tool steel Particle-reinforced		Al2O3 Cordierite		ATZ Si3N4		Super-INVAR

 

Generic ceramic and metal demonstrators

The metal demonstrator is a freely available design demonstrator based on the template of the RTC Duisburg (link to download CAD file). The ceramic demonstrators of the Fraunhofer IKTS are adapted to the respective fields of application (porous structures, high-performance ceramics).

The aim is to demonstrate that a form-complex structure is possible with the new materials. The demonstrators will be built with new powder as well as with recycled surplus powder. In a target-performance comparison between CAD and demonstrator, the dependence of the geometric possibilities of technology and material will be quantitatively investigated.

 

Functional demonstrator (© Airbus)

It is a real component from the field of satellite technology, which thus already exists conventionally and in a powder bed made of INVAR. The aim is to demonstrate that the new material Super-INVAR can also be used to produce such a complex-shaped structure with cost-saving potential compared to conventional production. The mechanical properties of INVAR are to be retained while improving functionality.

 

Process technology and plant engineering

Conventional laser head

Technology development laser deposition welding

In order to improve quality and resource efficiency in laser cladding, the aim is to monitor the filler metal supply and other process signals, which are correlated with numerical predictions. The development of coaxial direct diode lasers (kDDL) for both wire and powder processing also enables good material and energy efficiency.

Further developments in process simulation will also improve the predictability of distortion and residual stress as well as parameter design.

By using robot-guided contour recognition systems, geometric process limits in the manufacture of large components are overcome.

 

Demonstrators
HYBRID 1 - cutting tool		HYBRID 2 - turbine housing
	Requirements • Highest wear properties • High stability • Reduction of the post-processing effort Barriers to be overcome   • Evaluation of new materials (particle reinforced materials) • Cross-process manufacturing (conventional and additive) • Material combinations		• Compliance with aviation quality standards • Component dimensions of over one meter       • Reproducibility • Resource efficiency (materials and energy) through process head development and process simulation • Process combinations (conventional and additive) • Production of large components Robotics
HYBRID 3 - housing of a safety valve		HYBRID 4 - Injection moulding tool
	Requirements Large component (~ 0.5 m) with high form and accuracy requirements Integration of functional elements       Barriers to be overcome Increase of the contour accuracy Reduction of manufacturing costs Combination of different additive processes Multi-material processing Resource efficiency through process time reduction and process head development Production of large components		Cooling close to contours Cycle time reduction during the injection moulding process   Evaluation of new materials (tool steel) Material combinations Extension of the geometric boundary conditions by the combination of different additive methods Resource efficiency