FAB-LIGHT - Modeling of Sustainable AM ​​Processes for the Fabrication of Lightweight Products

Manufacturing large complex gas turbine components using L-PBF is challenging with regard to material structure and defects during the build stage and subsequent heat treatment, e.g. build stop, delamination against support structure, cracking at thickness transitions and geometry deformations. The project will identify the right model complexity by developing, calibrating and apply material and FE models suitable for thermo-mechanically coupled analysis that can predict with sufficient accuracy the fabrication. A www.vinnova.se Utlysning inom SIP LIGHTer www.lighter.nu combination of several analysis tools linked to before, during and after manufacturing will be used, 1) Numerical simulations (2) In-situ monitoring 3) Validating experiments after manufacturing. Potential and competitiveness for weight reduction increases as an effect of the project through reduced development time, greater design freedom with the help of optimization and improved quality and reduced material waste compared to casting or forging.

Validated analysis tools and methods from the project are necessary to move forward with circular material flow, net-zero material and energy consumption and sustainable circular material Evaluation and demonstration of new variants of manufacturing process chains for products and expertise on effective methods for AM process chain simulation helps to reduce expensive trial-and-error attempts throughout the supply chain.