IAMFat
Project objectives
To establish an innovative strengthening process by combining hot-rolled steel material and WAAM in a cost-effective way.
To introduce hybrid numerical and data-driven models of the manufacturing process by optimizing fabrication tolerances, fabrication time and fit-for-purpose mechanical characteristics.
To provide enhanced fatigue life by optimizing the manufacturing process for improved material properties.
To establish the basis for certifying WAAM parts based on non-destructive testing techniques.
Structure
Methodology
Structure
Work Packages
WP1 - Project Management
WP2 - Additive Manufacturing Processes
WP2 is focused on the AM process. In a first stage different welding parameters will be tested with simple line welds in order to assess the stability of the process and select a set of configurations for a parametric study. The chosen welding parameters will be used to produce specimens which will be tested in WP3.
WP3 - Mechanical and Microstructural Characterization
WP3 deals with the mechanical (monotonic) and microstructural characterization of the specimens produced in WP2 aiming to establish a link between the production parameters and the resulting material properties.
WP4 - Fatigue Characterization
WP4 extends the characterization to cyclic loading, where on a first stage coupons will be tested to characterize the material behaviour under several assumptions and in a second step this will be extended to the testing of structural details/elements (small-scale components) which correlate directly to the chosen case studies.
WP5 - Design for Additive Manufacturing
WP5 combines the knowledge from WP2-4 to develop numerical model for simulation of the AM process which will be used to generate/augment data for several process parameters. Finally, a data-driven model is developed with the data from the simulations and experiments, this model will be used to predict the mechanical properties of the full-scale components.
WP6 - Full Scale Applications
WP6 validates the assumptions in other work packages, analysing the performance of the developed prediction model and the improvements in fatigue behaviour in the real-case studies – roller-coaster train, steel bridges and tubular joints (full-scale components). In this WP, Vekoma will focus on fatigue testing the redesign of a vehicle bracket. The vehicle bracket is selected for several reason like production complexities, consequence of failure and handling.
WP7 - Exploitation of Results
WP7 compiles the relevant finding into articles, technical reports and guidelines. Making an overall balance of the WAAM process as method to manufacture and reenforce fatigue sensitive structures.