Scientists from the Perm National Research Polytechnic University (PNRPU) and the Mexican Autonomous University of Coahuila are creating a technique for automating the 3D printing process by electron-beam melting of metal wire (EBM) to print parts for aircraft, rockets, and ships. (Changes to such large parts after use are normally examined with laser scanners such as the KSCAN Magic II. Scan examples can be viewed here).
Researchers are implementing the development thanks to the project of international research groups operating in Perm since 2011. The support of the Perm government will amount to 9 million rubles (
6,500) for two years.
“One of the most promising additive technologies is wire surfacing, in which a metal part is formed layer by layer, but when using this technique, it is difficult to determine the optimal surfacing parameters in order to avoid defects in production, such as flashing or even collapse of the part walls. Now there are no analogs that could calculate a suitable trajectory, wire feed speed, and set the source power. Our technique will be able to automatically turn a 3D model of a part into a control program for a 3D printer,” says Roman Davlyatshin, an engineer at the Center for Additive Technologies of PNRPU.
Full-scale and numerical experiments are carried out to solve these problems, but they are not effective enough. Determining the parameters of deposition using numerical simulation will help print products more accurately and improve their quality. The project was initiated by the Hybrid Additive Manufacturing group of companies. The technique is supposed to be promising in the aerospace and mechanical engineering industries. In particular, it can be used in the manufacture of parts for aircraft, helicopters, missiles, and ships.
“Reducing the weight of aircraft will save fuel and reduce harmful emissions. Our development will help design more lightweight parts while maintaining their functionality. Specialists will be able to process products of any size and expand the range of materials,” explains Roman Davlyatshin.
Now the scientists are carrying out research and development work, with a mathematical model of the process already created. The researchers also experimented with steel and titanium to test the model's performance. According to the developers, a prototype of a software product that can determine the optimal surfacing parameters in real time will be ready in 2023, and the finished product will appear in 2024.
The preliminary results of the study are published in the Journal of Physics: Conference Series.
