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IK4 Doctorados

 

LORTEK

Industrial projects research oriented companies of manufacturing industry.

 
DOCTORATES

LORTEK

PhD position in Wire and Arc based Additive Manufacturing (WAAM) – mechanical performance and metallurgical analysis of parts manufactured by double wire arc processes

LORTEK

START: 10/2018

OPEN

OBTAINING DOCTOR DEGREE: 10/2018

Description

A PhD position in WAAM technologies is open. PhD student will join Process Department of IK4-LORTEK and research group of WAAM technologies.

The aim of the PhD work is to develop a cost effective manufacturing process of aeronautic parts made of Ti and Al based alloys by WAAM. These alloys are largely used in aeronautical parts and structures. We are targeting Ti and Al based parts with high buy-to-flightratios such as:

1) Fuselage parts or structures made of Ti6Al4V (Gr.23).

2) Fuselage parts or structures made of high strength (2XXX, 7XXX or similar) aluminium alloys.

The goal is to manufacture weld bead by bead and layer by layer near net shape parts. Robotics systems should be used together with suitable CAD/CAM systems available at IK4-LORTEK.

The innovation is based on the use of double wire arc welding process (CMT TWIN technology) in order to provide high deposition rates (critical for economic feasibility against machining) and to make in situ chemical reactions leading to the required chemical compositions.

Concerning Ti6Al4V, IK4-LORTEK has expertise with CMT process. We have manufactured walls and simple parts without internal defects and good mechanical properties after dedicated thermal treatment (scientific papers are available). Our best deposition rates for single CMT process was 2.3 Kg/h. The challenge is to increase deposition rate up to 5 Kg/h in order to be competitive with other high deposition rate processes (EBAM, Rapid Deposition Plasma) (both patent pending processes). This will require the adjustment of the process parameters to be used in CMT TWIN process.

On the other hand, since different filler metal can be used in each feeding system integrated in CMT TWIN, we are interested in adjusting chemical composition of final weld bead by combining commercially available filler metals, wire diameters and feeding rates. The goal is to use this concept for developing in situ 2XXX and 7XXX chemical compositions by combining weldable aluminium wires (Al-Cu + Al-Mg alloys). This will require adjustment of CMT TWIN process.

PhD student will focus his/her scientific work on:

  •          CMT TWIN based WAAM process development of targeted alloys.
  •          Optimization of process parameters
  •          Definition of deposition strategies to ensure even building
  •          Advanced metallurgical characterization of parts-
  •          Mechanical characterization of parts

Department or unit of the Associates Technology Center

Processes Area

Investigation line

Additive Manufacturing

Start date planned

10/2018

Obtaining date of the doctor degree

10/2018

Requeriments

-          Master of Science degree in Engineering (MScEng), Chemistry or Physics.

-          Master of Engineering degree (MEng), Master degree in Chemistry of Physics

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