Net-shape joining technology to manufacture 3D multi-materials components based on metal alloys and thermoplastic composites

Summary

ComMUnion enables productive and cost effective manufacturing of 3D metal/ Carbon Fibre Reinforced Thermoplastic (CFRT) multi-material components.ComMUnion will develop a novel solution combining tape placement of CFRTs with controlled laser-assisted heating in a multi-stage robot solution. High-speed laser texturing and cleaning will overcome the limitations of current joining technology to provide greatest performance joints.

ComMUnion will rely on a robot-based approach enabling on-line inspection for layer-to-layer self-adjustment of the process. Moreover, tools for multi-scale modelling, parametric offline programming, quality diagnosis and decision support will be developed under a cognitive approach to ensure interoperability and usability.

ComMUnion will address the following key innovations:

  • Texturing and cleaning based on high speed laser scanning for surface condition.
  • High-speed spatially resolved control of surface temperature profile.
  • Multi-scale metal/CFRP modelling, self-adaptive process control, and quality diagnosis based on multimodal active imaging.

ComMUnion approach will decrease by 30% the consumption of titanium and boron steel, (costly alloys requiring critical materials).

Besides, reinforcement of textured metallic surfaces with CFRT tapes will increase mechanical performance of multi-material components over 30% without cost increase.

Manufacturing of two pilot-cases for automotive and aeronautics will demonstrate the scalability of the joining process.

It will be possible trough a consortium with a strong involvement of industrial partners (73% of which 55% are SMEs).

The outline of the business plan ensures the exploitation of the project results. With a target market of 2.000 companies and a fair estimate of 2% market penetration (5 years after the commercialization start), ComMUnion will result in 40M€/year incomes.

More information
Web resources: http://communionproject.eu/
https://cordis.europa.eu/project/rcn/199470/factsheet/en
Start date: 12-01-2015
End date: 31-05-2019
Total budget - Public funding: 5 917 392,00 Euro - 4 863 011,00 Euro
Call topic: Industrial technologies for advanced joining and assembly processes of multi-materials (FoF.NMPB.2015.12)
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Innovation Action (IA)

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Economic sustainability Supply chain and value network efficiency Flexibility
Circular economy Material efficiency

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Manufacturing the products of the future Novel materials Complex structures, geometries and scale
Customised products Resource efficient, sustainable products Domain 2: Adaptive and smart manufacturing systems

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Advanced manufacturing processes Innovative physical, chemical and physicochemical processes Integration of non-conventional technologies and conventiona... Recycling processes Control technologies
Intelligent machinery components, actuators and end-effectors Measurement, condition and performance monitoring technologi... Advanced materials in manufacturing systems Modelling and simulation for the (co-)design and management ...

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