Controlled characteristics materials produced by wire + arc additive manufacturing – MACCADAM
In the last past years, Additive Manufacturing (AM) processes have been intensively developed leading to a revolution in many industrial sectors. These processes offer the possibility of developing parts of complex geometry and high mechanical strength, with short manufacturing times and with important raw material saving. However, conventional metallic AM processes suffer from the prohibitive cost of raw materials, in a powder form, and low deposition rates, increasing manufacturing times and limiting the dimensions of the produced parts. In this context, the MACCADAM project aims to promote the industrialization of a new arc-metal additive manufacturing process derived from welding and based on the deposition of successive layers of a metallic wire melted with an electric arc. This original process differs from other traditional AM processes by allowing high material deposit rates and the use of low cost and easy to use massive products. MACCADAM proposes to solve several issues that still limit the use and diffusion of this innovative process. The aim of this project is to :
1) identify potential applications of this new process based on a comparative analysis of the respective characteristics of the arc-metal process and the other AM processes;
2) identify the process parameters (electric parameters, protective gas, layer stacking strategy ...) leading to optimal geometrical characteristics and limiting the distortions due to residual stresses, for two materials chosen for their industrial interest (316L stainless steel and TA6V titanium alloy);
3) carry out a microstructural and fatigue resistance characterization of the materials in order to assess the parts mechanical properties according to the manufacturing parameters set;
4) model the solidification process of the deposits in order to predict the microstructures and associated mechanical behavior with numerical simulations.
MACCADAM gathers academic and industrial partners specialized in the fields of additive manufacturing processes (LMGC, Poly-Shape), materials characterization (ICA, LGP, LMGC) as well as modeling and numerical simulation of forming and manufacturing processes of metallic materials (CEMEF). Ultimately, MACCADAM intends to promote the diffusion of this new process in the industrial world, within a controlled framework, to guarantee the production of high performance parts at a reduced cost.
Monsieur Frédéric Deschaux-Beaume (Laboratoire de Mécanique et Génie Civil)
The author of this summary is the project coordinator, who is responsible for the content of this summary. The ANR declines any responsibility as for its contents.
LMGC Laboratoire de Mécanique et Génie Civil
LGP LABORATOIRE GENIE DE PRODUCTION
PS POLY SHAPE
ARMINES (ICA) ARMINES
Help of the ANR 709,567 euros
Beginning and duration of the scientific project: March 2018 - 48 Months