Periodic Reporting for period 1 - ComMUnion (Net-shape joining technology to manufacture 3D multi-materials components based on metal alloys and thermoplastic composites)

Summary

ComMUnion aims to enable productive and cost-effective manufacturing of 3D metal/ Carbon Fibre Reinforced Thermoplastic (CFRT) multi-material components. Thus, it will develop a novel solution combining tape placement of CFRTs with controlled laser-assisted heating in a...\n\nComMUnion aims to enable productive and cost-effective manufacturing of 3D metal/ Carbon Fibre Reinforced Thermoplastic (CFRT) multi-material components. Thus, it 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 technologies to provide great 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.

During this 1st period the work performed in ComMUnion contributed, mainly, to the fulfilment of four out of the eight main objectives. The objectives together with the main achievements of the period are listed below;

O1: Developing a new multi-stage joining robotic solution

  • Laboratory tape-laying system and laboratory texturing head have been designed
  • Industrial tape placement heads have been designed
  • Definition of the communication protocol standard for data exchange between modelling software and joining process control.
  • XML structured has been performed
  • Cell lay-out for subsystem integration has been defined

O2: High efficient and flexible surface condition solution

  • Industrial polygon scanning texturing head has been designed
  • Process window has been adjusted and, accordingly, the dataset of laser parameters has been obtained for the different metallic materials of the study cases
  • Structured surfaces screening has been performed for the different metallic materials of the study cases

O3: Developing a multi-scale modelling system

  • Macroscopic simulation of the two pilot cases have been performed
  • Multi-scale analysis of hybrid joint performance has been attained and the required models has been developed
  • Process simulation at a multi-scale level. Models for tape laying, laser texturing and VCSEL heating has been developed

O4: Implementing an embedded flexible control of the laser-assisted heating profile

  • VCSEL system development
  • Design and prototype development of a high- speed camera (10kHz framerate)
  • Preliminary software for RT control of the system

O5: Developing QDS in a multi-stage manufacturing approach based on active imaging techniques

  • The hardware configuration of the speckle-pattern inspection system and the corresponding algorithms have been developed
  • Active thermography system for defect detection, while laying the composite tapes, has been accomplished

O6: Self-adjustment of process parameters

O7: Demonstration of recycling/reuse by direct heating of the metal

O8: Demonstration of a fully automated 3D joining multi-material technology applied to automotive and aeronautics

  • End-user requirements has been specified and two study cases has been identified
  • ComMUnion system's requirements have been defined, which implies the definition of the functional requirements of the different subsystems involved.

1) A new texturing system was successfully assembled, adjusted and characterised for multi-pass texturing of lines with undercut with scanning speed of 20 m/s
2) An uncooled imaging Focal Plane Array IR camera with spatially resolved temperature distribution measurement capabilities has been designed with a high framerate (i.e. 10 kHz). Also this includes the development of a new and improved sensor with better capabilities, more resolution and higher sensitivity, able to acquire images at lower temperature than previous model.
3) New and flexible customize VCSEL modules have been developed, which allow to attain adjustable heating profiles useful to modify power densities distribution to different joint geometries.

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