COMSENSO. Project Description.
Currently, additive manufacturing (AF) technologies, and in particular Direct Energy Deposition (DED) technologies, including Wire-Arc Additive Manufacturing (WAAM) technology based on GMAW (Gas Metal Arc Welding) process, are attracting increasing interest from the industry and experiencing a very significant growth. Despite achieving a high contribution rate, WAAM technology does not yet compete with traditional manufacturing processes, which is mainly due to the difficulty of guaranteeing the quality of the manufactured part and the lack of process stability.
The main objective of the COMSENSO project is to develop a new additive manufacturing technology for metal components based on laser-assisted WAAM (L-WAAM) technology, which will overcome the main barriers faced by AF, namely: achieving high productivity and guaranteeing the manufacture of multi-material components with zero defects.
Therefore, the aim is to develop a new additive manufacturing process oriented to the fabrication of large parts. In particular, the project will address multi-material systems in steel/invar and stainless steel/Inconel for the aeronautical and metal-mechanical sectors, although the developments will be extrapolated to many other sectors (railway, energy, etc.).
To this end, COMSENSO aims to achieve the following technical objectives:
1) Development of the L-WAAM process:
a. Development of a new high-power, fiber-coupled diode laser source.
b. Development of an L-WAAM head that allows combining the laser beam with the electric arc.
c. Development of the process of embedding FBGs sensors in fabricated parts for in-service monitoring.
2) Development of a digital L-WAAM platform:
a. Generation of a digital twin of manufactured part.
b. Development of an online process monitoring and control system based on the capture and analysis of images taken by an infrared camera.
c. Development of an intelligent manufacturing assistance system capable of predicting the appearance of possible defects in the part.
3) Development of an integrated L-WAAM cell:
a. Fabrication of demonstrator.
b. Technical-economic analysis of the solution.
c. Product life cycle analysis.
For more information visit the project website: http://www.comsenso.es
Expediente: MIP-20211010
Acrónimo: COMSENSO
Denominación: FABRICACIÓN ADITIVA MEDIANTE TECNOLOGÍA WAAM ASISTIDA POR LÁSER DE COMPONENTES MULTIMATERIAL SENSORIZADOS
Concedido (€): 247.982,57 €
Duración: 2021 -2023
Descripción: Programa Misiones CDTI, convocatoria 2021. This project is funded by the Ministry of Science and Innovation and “Subsidized by CDTI”.
