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  • Cell. Competence Center of Additive Manufacturing based on High Deposition Rate by direct deposition of powder and wire (LMD and WAAM)

    Pilot cell for the application and comprehensive development of metallic additive manufacturing in Directed Energy Deposition technology. Equipment, resources, software (CAD-CAM), knowledge related to additive manufacturing (LMD and WAAM) are made available for the companies. This also includes the study of the process industrialization and the integration of those processes in the production chain (combination of the total flow of manufacturing from the powder/wire to additive manufacturing process, heat treatments, machining and surface treatments). It is available: - 4 robotized cells - A gantry (7 x 3 metres) - 2 facilities of 3 axes (possible to include a fourth rotation axis) - LMD-powder. These facilities are able to combine with three optics and nozzles for LMD (one of them is capable of controlling the deposition width in real time). It is possible to simultaneously feed with two different materials. WAAM-wire_with PAW, TIG and CMT technologies (Fronius) with different technologies of deposition path control (equipment continuously updated 2017). It is provided the possibility of working with reactive materials like titanium (in controlled atmosphere) and with control systems of local atmosphere (with local protection system, in development by Addispace project). This infrastructure currently presents a series of sensors to the capture of process data (developed in COMBILASER project 2015-2017) and it is possible to establish the required connectivity for ICT platforms. Finally, it is worth noting, the development of a CNC systems of Fagor provided with an accessory to process control (laser) based on optimized parameters database and scalable to any machine with a CNC control of Fagor Automation. It should be noted that it is also provided a platform of LMD process control with optical and thermographic process sensors): - to CNC advanced environments - with LABVIEW platform control - connectable to platform or IoT infrastructure

      MOST OUTSTANDING EQUIPMENT AND COMPONENTS

    • Arc welding processes: PAW, TIG, CMT
    • Fix and floating optical head
    • Four robotized cells: ABB robot, robot ASEA IRB 2000, Robots FANUC 1 and FANUC 2
    • Laser disco 5kW, Laser Nd-YAG 3 kW, diode laser 3kW, fiber laser IPG 1kW
    • Powder feeder of 2 units with heating

    Fields of application

    AM Digital Chain.

    AM process validation

    AM/3D Printing Process

    Design for AM and Digital pre-processing

    Materials for 3D/AM

    Post process

    Supporting technologies and processes

    SERVICES OFFERED BY THE ASSET

    Additive manufacturing integration in industrial productive processes. Hybridization of processes.

    Connect machines of different processes (LMD and/or WAAM) with subtractive (machining, etc) to improve the efficiency of the productive process.

    Bring technology to the companies and related opportunities and risks.

    Bring additive manufacturing technology close to the environment and basque companies and this potential benefits and business opportunities. Orientation about achievable mechanical properties and microstructure.

    Parts manufacturing by LMD

    Possibility of programing paths in CAM environment (for cartesian systems and robots, TEBIS, Autodesk, power mil,…). Prototypes manufacturing and final part with high added value (including post-processing) (steel, Ti, Ni alloy, Al). Parts manufacturing with controlled coating with high performances. Geometrical distortion control in complex part manufactured by additive manufacturing technologies of high deposition.

    Smart process controlling and temperature and melt pool size monitoring during LMD process

    It is provided a thermographic camera (camera and pirometer) and other CCD camera for temperature and geometry of the met pool monitoring, respectively, to an optimal LMD process control (closed-loop). Process parameters´ optimization including shielding gas in the case of WAAM processes.

    Surface treatments and repairs of parts manufactured by LMD

    Optimized surface treatments development to obtain optimal final properties, taking into account the metallurgy of each alloy, thermal history of the deposition process and application requirements.

    Test (materials, characteristics,…) including powders and assess their processability

    It is provided an open platform to develop parameters and process for new materials and the possibility of characterizing them until achieve the optimization.

    Test ICT systems related to simulation and CAD-CAM-CA_x in a controlled environment prior to their commercial deployment

    Test ICT systems related to simulation and CAD-CAM-CA_x in a controlled environment prior to their commercial deployment. Possibility of testing data platforms to process control (Data Analysis and Big Data).

    Training

    Access to people to different levels, from technicians, engineers to other profiles for their introduction and training in technology to achieve an adequate technological criterion.

    ENTITY MANAGING THE ASSET

    LORTEK S.C.
    Contact person:
    Emma Gil Murillo