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IK4 Doctorados

 

TEKNIKER

People whose vocation are focused on enhancing the innovative capabilities of their customers and furthering their technological capital.

 
DOCTORATES

TEKNIKER

Development of the deposition process through direct laser fusion of the material for the additive manufacturing of functional structures and components in metal alloys

TEKNIKER

START: 10/2016

COVERED

OBTAINING DOCTOR DEGREE: 10/2019

    Description

    Laser Metal Deposition (LMD) is one of the techniques for manufacturing metal components and structures that has seen the greatest progress in recent years.

    The technique consists of laser fusion of metal material, either in the form of powder or wire, injected onto the surface of a substrate in order to obtain dense structures of a specified shape.

    The method is used in numerous applications, generally as a protective coating against wear and corrosion, or in the repair of components in various industrial sectors, such as the mould and matrix industry, the medical implants and instruments sector, the aviation, railway, automotive industry, etc. It has recently been used to manufacture three-dimensional metal components.

    Compared with the additive manufacturing methods using pre-deposited powder bed (Selective Laser Melting or Electron Beam Melting), LMD technology allows high deposition rates and the manufacturing of large-size components. Yet, despite the described benefits, the growing interest of various industrial sectors (aviation, automotive, biomedical, etc.) and the boom in the technology, there is still a long way to go to fully meet market needs and this aspect has yet to be solved. For example, the industry is increasingly calling for manufacturing technologies for high-added value metal components with high deposition rates (> 5 Kg/h) and therefore speed of manufacturing, good reproducibility and finish with the minimum of material wasted and polluting emissions. It is also calling for the availability of more flexible technologies capable of producing large-size parts with identical mechanical properties as those of a lower weight and size. Finally, the industry is asking for costs to be lowered through the cut in fixture times, and in the adjustment and taking of reference points.

    It also wants the number of operations needed to manufacture a component to be reduced, and the transfer of the component from one machine to another to be avoided during the various manufacturing processes.

    This PhD thesis aims to develop the deposition process using the LMD technique in order to manufacture structurally functional metal components.

    The study will be focussing on deposition strategies as well as on the analysis of process parameters and variables to allow different types of structures to be manufactured, with work being carried out on thin walls, solid structures, sloping walls, cylinders, supports, support structures, the design of them, etc.; such structures should be defect-free (pores, cracks, oxidation) and have good micro-structural quality. The main points to be developed are summarised as follows:

    a) The study of optimum parameter conditions in the process to manufacture large-size structures with high deposition rates and process efficiency.

    b)    The determining of the deposition methods: specification of the limits of the technology (critical angle, reinforcement structures, etc.) and optimum deposition strategies to achieve improvements in productivity and geometric quality with respect to large-size parts and simple geometries.

    c)     Development of in-process closed loop control systems to optimize the structural and geometric quality of the part being manufactured.

    Department or unit of the Associates Technology Center

    Advanced Manufacturing Technology Unit

    Investigation line

    Additive Manufacturing

    Start date planned

    10/2016

    Obtaining date of the doctor degree

    10/2019

    Requeriments

    - Engineering or Physical Sciences (degree or Master’s). The degree must allow access to a Doctorate Programme consistent with this PhD offer. Advanced level of English.
    - Knowledge of materials science, l-monitoring, programming skills (Matlab-Simulink, LabView, C, FEM, etc.), data processing and a prior knowledge of systems control will be a great asset.
    - A vocation for research, initiative, and a problem-solving capacity are essential.

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