Projet AMOS - Additive repair for Aerospace

AMOS


New European-Canadian research to explore additive repair for aerospace

 

AMOS project objectives and details

 

AMOS is investigating a number of additve manufacturing (AM) processes which can be used for repair of aerospace components such as turbine blades and landing gears. Damaged components can be repaired (on-demand) and material lost in service can also be re-deposited to restore the component to its original shape. This approach has the potential to reduce lead times, cost and material waste and to extend the service life of damaged or worn components.

The partners will carry out fundamental research to understand the resultant material properties of a number of direct energy deposition (DED) processes for three different materials. They will investigate the accuracy and limitations of these deposition processes, effective defect geometry mapping and generation methods, and automated and hybrid DED and post-deposition machining strategies. Both powder- and wire-based DED systems will be investigated to establish an across-the-board comparative study.

 

The data collected will be extremely valuable for the large companies who are partners in this project (GKN, PWC, and HDI) allowing them to understand the pros and cons of these systems and helping them to select suitable repair and re-manufacturing additive technologies. The tests conducted in this research are also extremely beneficial for the SMEs in this project (Liburdi and DPS) to validate and improve their existing repairing systems and techniques.

 

Common additive processes are typically controlled either by a CNC controller or a robotic controller depending on the type of machine that carries the deposition nozzle system. Therefore, both CNC and robotic systems will be studied for both powder and wire feedstock using lasers or Tungsten welding as a power source. Three aerospace alloys will be investigated: Ti-6Al-4V, Inconel 718, and 300M alloy steel.

 

The specific objectives are to:

  • Study the process accuracy, repeatability, limitations and material integrity of the different systems under consideration

  • Develop an effective system to generate the repair geometry

  • Develop accuracte models to simulate the different deposition processes

  • Develop a method to optimise component design for additive repair

  • Establish the qualification procedure to allow suitable technologies to be used for repair and remanufacture

DPS work packages

DPS is involved in two work packages:

WP3 - Develop accurate thermomechanical model for the simulation of powder and wire deposition processes

WP5 - Develop a design optimization system to improve existing aerospace component design based on the damage type and repair strategies

European and Canadian Partners
 

The European partners are the University of Sheffield AMRC in the UK; Ecole Central de Nantes in France; GKN Aerospace Engine Systems, based in Sweden; and DPS, a French SME specialising in process simulation and optimisation.

Canadian partners are McGill University, Montreal; the University of Ottawa; jet engine manufacturer Pratt & Whitney Canada; landing gear supplier Héroux-Devtek; and automated welding specialist Liburdi.

European and Canadian funding

The four-year, €2.6 million (C$3.8 million) project is supported by the European Commission through the Horizon 2020 programme and by Canadian funding agencies CARIC and NSERC. It is one of the first European-Canadian projects to be funded under the 'Mobility for growth' collaboration in aeronautics R&D

Le consortium

Pratt & Whitney, a United Technologies Corp. company, is a world leader in the design, manufacture and service of aircraft engines and auxiliary power units.

Company website

GKN specialises in design and manufacturing of highly loaded engine components and sub structures as a tier one supplier to Major OEM’s.

Company website

McGill University is the leading research intensive university in Canada. The participating academics from McGill university are leaders in the AM research field.

Company website

DPS specialises in providing tools and consulting in order to enable Simulation-Based Design. DPS has a strong experience in CAD/CAE integration and more globally in simulation and optimization.

Company website

Ecole Centrale de Nantes is a research and education institution. Main fields of interest and competence are: Engineering of Industrial Systems / Automatic control/ Computer Sciences / Product Design and Manufacturing,...

Company website

The University of Ottawa is one of Canada’s leading research-insensitive universities. CENTRE FOR RESEARCH IN PHOTONICS is one of the best in North America.

Company website

Heroux-Devtek is a manufacturing company specializing in the design, development, manufacture, integration, testing and repair and overhaul of landing gear and actuation systems and components for the aerospace market.

Company website

Integrator of automated solutions. Specialized in aerospace for Visual Inspection and Robotic Finishing.

Company website

The University of Sheffield is one of the leading research Universities in the UK. All Departments in the Faculty of Engineering were classed as 5 or 5* in the last research assessment exercise (RAE), research in advanced manufacturing exceeds £20 million.

Company website

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