Nicolas CORREGE, Chef du Service Impression 3D
At a time when environmental issues are at the heart of concerns, industrial players in the aeronautic sector are evolving toward the development of more electrical products. The performance and the volume constraints of these equipment have to be taken into account, and the current technologies are not answering fully these new requirements. Additive manufacturing, an innovative technology, is very relevant for thermal applications. PrintSky (joint-venture between SOGECLAIR and AddUp) will present its revolutionary heat exchanger in metallic additive manufacturing, developed in partnership with Temisth. It has an innovative geometry that allows optimized integration in a constrained environment and allows to meet the challenges of tomorrow.
The value provided by Additive Manufacturing (AM) has been found to be immense by the Aerospace industry, despite the sophistication of the technology,. AM is being, step by step, integrated into the product development as well as manufacturing strategies in the aerospace industry. EOS’ presentation will showcase the latest status of AM adoption in Aerospace. It will focus on 2-3 of the most mature applications, in terms of criticality & business case, both in Polymer & Metal based AM for Aerospace. The key success factors for these applications & projects will be highlighted.
LISI AEROSPACE Additive Manufacturing
For years, DASSAULT AVIATION and LISI AEROSPACE ADDITIVE MANUFACTURING have worked together in order to develop the range of serial flying parts made by Additive Manufacturing (AM). The first parts identified as candidates to be manufactured with AM were in stainless steel, which led to the qualification of a dedicated machine. Different aircraft programs are concerned and problems to be solved are various : small serial quantity of complex parts for the RAFALE, highly-finished products on F8X, ATL2 retrofit or customization products for F2000 MRA. On each of these aircrafts, LISI AEROSPACE AM supports DASSAULT AVIATION by providing its know-how to manufacture high value added products that benefit the most from the technology and works closely with the design teams to optimize the design of the products. In order to further enlarge the range of products, DASSAULT AVIATION has decided to qualify our Concept Laser X LINE 2000R on AlSi7Mg0.6. Goal: manufacture in 2020 the demisting tubing for the RAFALE in one component rather than welding different ones. Others parts will be progressively be added to the list of serial flying parts.
The "lattice" structures are likely to provide considerable added value for the aeronautics and space industry. The exploration of the potential of those structures by engineering offices is currently limited by the knowledge, tools and models available for their design and in-service behaviour. Through a multi-scale experimental and numerical approach, the IRT Saint Exupéry in collaboration with the IRT SystemX will present an original scientific and technological method to measure and quantify variabilities inherited from geometric, metallurgical and mechanical scattering. This method has been used to develop more robust industrial design tools for lattices structures.
The Directed Energy Deposition technology developed by BeAM is an Additive Manufacturing process where focused thermal energy is used to fuse materials by melting them as they are deposited. It opens a whole new range of applications for the repair, manufacturing and hybridization of parts, especially in the aerospace industry. The industrialization of this technology is accelerating with the design of specific machines, the extensive work of R&D platforms and the integration of advanced process monitoring systems.
X-ray microtomography is a powerful imaging technique that has proven to be an effective tool for non-destructive 3D inspection. Nowadays, it is more and more employed as a standard characterisation method in R&D applications as well as a means of control in production line. It can be applied to nearly all kinds of materials and types of parts. The use of X-ray synchrotron sources pushes back the limits of the technology and offers the possibility to inspect at high resolution large parts without cutting them. It provides outstanding image quality and enhanced phase segmentation capability thanks to phase contrast imaging mode. In addition, the high brilliance of sources allows ultra-fast acquisition for the follow-up of process in real time. The presentation will be based on concrete examples such as the rugosity characterisation of surfaces in AM parts inaccessible with conventional techniques, the dimensional control by 3D mapping the geometrical deviation from CAD files, or even the detection and analysis of cracks inside metallic components.
Illustrated by a real use case, we will present an original numerical solution using a fast, automated generative design solution linked to an SLM process simulation solution as well as a cost estimator, enabling you to qualify and rank different design concepts during the design phase of parts intended for SLM production