Development of 3D multi-material & multi-functional components through additive manufacturing assisted by the smart design of materials and process

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The MULTI-FAM project aims to manufacture 3D multi-functional and multi-materials components for the steel-making sector using different materials, through a direct energy deposition-laser based process using metallic powder (DED-LB-P). This additive manufacturing process will be assisted by an smart methodology comprising the intelligent design of materials and the process based on modelling and the thermodynamic simulation of different materials and their compatibility. In parallel, it will be designed the manufacturing process based on the optimal selection of the parameters and fabrication strategies as a function of the materials and the place to be deposited. Finally, Process monitoring and control systems will be developed to determine the geometry of the layers and the cladded material.
Among the different results of the project it can be highlighted:
- Additive manufacturing process based on DED-LB-P including a system for the monitoring of the powder flow
- Numerical modelling for the multi-material DED-LB-P process able to calculate the distortions of the component, determining the optimal fabrication strategies capable to minimize them.
- Thermodynamic modelling of multi-material systems, able to predict the potential formation of phases during the additive manufacturing process and to evaluate the long-term stability of the obtained microstructure under usual operating conditions
- Injection Nozzle as demonstrator developed with the new multi-material DED-LB-P methodology
AIMEN has a main role the development of the complete multi-material and multi-functional additive manufacturing process regarding the following issues: materials, process monitoring and control and the preliminary characterization of the processed samples as a process quality checking.

• Sectors: Aeronautical, Energy, Metal mechanical, Steel
• Financing programme: AYUDAS A PROYECTOS ORIENTADOS A LOS RETOS DE LA SOCIEDAD
• R&D&i: Additive manufacturing, high power and high throughput laser processing, Integrated monitoring and control systems, Laser assisted processing, Multimaterial systems
• Partners: AIMEN Centro Tecnológico, Instituto IMDEA Materiales
• Acronym: MULTI-FAM
• Ambit: National