Fotec Analysis and Know-how Switch, the analysis firm of the College of Utilized Sciences Wiener Neustadt, has developed important components for integrating additive manufacturing into industrial course of chains as a part of the worldwide joint undertaking ‘Advert-Proc-Add II’. The main focus was on automated post-processing utilizing ‘Hirtising’ – a mix of chemical, dynamic electrochemical, and hydrodynamic processes that doesn’t require mechanical processing. Hirtising, which relies on liquid media, additionally treats deep cavities and undercuts on printed elements, which means that assist constructions will also be eliminated. Many elements could be Hirtised concurrently within the machines.
A spotlight of Fotec’s contribution was the additional improvement of Hirtising. Constructing on the outcomes of a earlier undertaking, focused machining methods have been developed for supplies similar to Ti6Al4V and 1.4404 (stainless-steel). By adjusting the PBF-LBM course of parameters, machining allowances of solely 180 to 550 micrometres may very well be outlined. That is thought of an vital step in direction of material-saving, automated post-processing of 3D printed components. On the similar time, floor roughness values of Ra ≤ 5 micrometres have been achieved, enabling exact functionalization of such elements. The undertaking additionally pursued the characterization of additively manufactured surfaces and the event of databases for course of optimization.
Fotec performed in depth investigations into the floor integrity of additively manufactured elements. The goal was to analyse how completely different PBF course of parameters, construct orientations, and intermediate therapies have an effect on the ultimate floor properties. A specific focus was positioned on the interplay with processes similar to shot peening (blasting), warmth therapy, and CNC kind grinding. The ensuing floor matrix offers a sound foundation for the focused mixture and optimization of additive and subtractive course of steps.
A major contribution to digital consistency on this space was the event of a cross-process knowledge administration system, which was created within the present undertaking by the Institute for Manufacturing Know-how and Photonic Applied sciences at TU Wien in collaboration with undertaking companions. A prototype hybrid CAM system was provided with multi-sensor-supported real-time knowledge, which was used to generate instrument paths robotically. The combination of sensor expertise, materials knowledge, and geometry info has enabled the event of an ‘clever’, adaptive CAM management system, which represents a milestone within the automation of complicated ASM (additive-subtractive manufacturing) course of chains.
The Fotec outcomes have been characterised by a excessive diploma of software orientation. Through the undertaking, check specimens and use instances have been manufactured and analysed from supplies similar to Ti64, 316L, and AlSi10Mg. Shut cooperation with the 15 industrial companions – together with firms from the aerospace, toolmaking, and medical expertise sectors – ensured that the processes developed could be instantly transferred to actual manufacturing situations.
The undertaking, funded by the Austrian Analysis Promotion Company (FFG), the German Federal Ministry for Financial Affairs and Local weather Motion (BMWK), and the Flanders Company for Innovation & Entrepreneurship (Vlaio) – coordinated by the ecoplus Mechatronics Cluster, FKM, and KU Leuven – aimed to make additive-subtractive manufacturing chains economically viable, even for small and medium-sized enterprises (SMEs). Fotec acted as a pacesetter within the subject of laser powder mattress fusion (PBF-LB/M) and electrochemical and mechanical post-processing.
