Technical feasibility study NIWAAM

„Additive manufacturing of complex moulds and tools made of 1.3912 for the production of components made of carbon fibre and glass fibre reinforced plastics (CFRP, GFRP)“

The aim of the project was to develop a technology for the additive production of multi-dimensionally moulded structures made from the material FeNi36 (hereinafter referred to as 1.3912). The background to this is the search for a way to manufacture extremely cost-intensive milled components, which are used in the manufacture of laminating devices in the aviation industry, much more cost-effectively and flexibly using a near-net-shape, additive welding process.

For this purpose, an allowance model is created from the CAD data of the part to be manufactured using appropriate software, the model is digitally divided into print layers and then, as can be seen in the illustrations above, print layer by print layer is applied using arc welding technology. As part of this feasibility study, the basic method of this process, known as WAAM (Welding Arc Additive Manufacturing), was transferred from conventional materials to the material 1.3912.

Based on extensive work, additive layer applications, from one-dimensional to multi-dimensional structures, were implemented in line with requirements. With the help of comprehensive data acquisition and analyses, a heat-guided process system was continuously developed for the creation of multidimensional layer applications. Furthermore, basic principles for order systematics and routines for complex structures have been developed. By transferring the findings to practically dimensioned components, the results serve as a reliable basis for further investigations.