AMICO - Additive Manufacturing and automatic process for hybrid and composite materials
Obiettivo
The Amico project is aimed at using of additive processes, namely to generate the component slice after slice and then to compose it into a 3D geometry using not necessarily powders or metal filaments, but carbon fibers and resins thermoplastic or thermosetting and realizing hybrid systems, consisting of different matrix materials and/or multifunctional capacities.
The approach will be tailored to the needs of 4 different industrial sectors: aeronautical, missile, automotive and pharmaceutical in a cross-fertilization optic. Appropriate manufacturing processes will be developed and an integrated design logic of the components to be built, based on innovative design philosophies, will be introduced. This approach will allow to implementing new efficient processes and convert existing configurations into more efficient ang lighter structures exploiting the peculiarities that additive technology makes available.
Developed processes will also be implemented in an Integrated System Logic, where the work center can produce a complete “one shot" manufacturing additive product, auxiliary processes for eliminating/reducing excess material such as supports, roughness and dimensional abnormalities and quality controls (NDI + dimensional) – in compliance with industry quality standards.
Attività nel progetto CIRA
CIRA contribution is focused on the aeronautics sector and supporting the needs of the industrial partners Aerosoft and Leonardo. This contribution finds space in three main streams:
Innovative manufacturing processes for thermoplastic composites based on additive techniques capable of producing near net shapes components, without expensive molds.
CIRA, with the support of the involved partners, has developed an innovative process based on an "Additive" approach, that integrates key aspects of several traditional manufacturing technologies for composites in a combined way (Figure 1). The process was validated on the lab scale with the manufacturing of a representative elements of the demonstrator identified by the industrial partners (spacer bushing for thermal insulation). The industrial partner Aerosoft is currently studying the scale-up of the developed process on its industrial production line.
Functionalization processes for multi-component systems: in cooperation with the CNR, an innovative process has been developed, which can be integrated into additive processes, for the development of thin thermosetting prepreg films characterized by a very high content of graphene. These films are able to give to the final structure, on which are integrated, specific functional properties, such as electrical conductivity and / or moisture barrier.
The produced films were integrated on surface of a sandwich composite panel representative of nacelle landing gear of the ATR aircraft in order to mitigate the absorption of moisture during operation and give to the surface conductive characteristics normally realized by special coatings. Tests conducted in the CIRA Space Qualification laboratory (Figure 2) have shown how the developed films slow down the absorption of moisture in the composite and guarantee the required conductivity characteristics to the surface of the panles.
Development of process / product diagnostic techniques for on-time monitoring of the process by non-destructive techniques: the aim was to identify experimental methodologies and / or software for the acquisition of data coming from non-destructive techniques, that can be processed automatically and allow the identification of a potential defect in the manufacturing process, from a quality control point of view (reduction of both waste pieces and the time required to check the conformity of the pieces).
In this context, CIRA has developed a methodology for rebuilding the 3D image of a metal component manufactured by EBM printing, processing the captured layer by layer images by the video camera positioned on board. The methodology, which also includes the use of neural networks, was tested with the manufacturing of cubic elements containing sample defects. The re-built 3D images were compared with real tomographic images, demonstrating excellent results (Figure 3).
Programma
The Research Project AMICO (code ARS01_00758) has been supported by National Operational Program on Research and Innovation funded by the Italian Ministry of Education, University and Research.
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data inizio:
Tuesday, October 23, 2018
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durata:
42.00
Tuesday, March 8, 2022
246
Tuesday, March 8, 2022
AMICO
Structures and Materials
The Amico project is aimed at using of additive processes, namely to generate the component slice after slice and then to compose it into a 3D geometry using not necessarily powders or metal filaments, but carbon fibers and resins thermoplastic or thermosetting and realizing hybrid systems...
Advanced Materials and Processes, Space Qualification Laboratory, Virtual Reality Lab
