In-situ monitoring and control of additive manufacturing for aeroengine component manufacturing

Important results from the project

RISE, GKN Aerospace and Procada have completed a joint project intended to verify Procada´s measurement technology for additive manufacturing. The measurement method has given new insight into the additive manufacturing process with metal wire and laser that GKN uses in production of aeroengine components. The method can be used to identify droplet formation or stubbing faster and with higher confidence than a process operator can. The parties intend to implement a fully automated system based on Procada´s measurement method to improve deposit quality.

Expected long term effects

The project has verified that Procada´s measurement system can provide new process information that can both contribute to better understanding of the process, but also be used for feedback control and prevention of droplets. In this way, Procada has been able to verify its equipment in an industrial environment with a prospective customer. GKN was given the opportunity to evaluate the new measurement equipment. Data has been collected that can support GKN in future decisions regarding measurement and control systems for additive manufacturing processes with laser and metal wire.

Approach and implementation

The project partners first implemented the measurement system in GKN´s equipment, after which data collection and analysis began. The measurement system was found to be compatible with GKN´s system for additive manufacturing. Several tests were carried out with different deposition tools and parameters. The data from these tests was later evaluated by Procada´s and GKN´s engineers. Based on the collected data it was concluded that the measurement method is particularly well suited for droplet detection and that a fully automatic system could be created based on Procada´s system.