Additive Technologies
Additive technologies allow the production of parts with complicated shapes composed of one or more materials. This makes it possible to achieve a reduction in the number of components, optimise weight and material intensity, minimise or exclude the number of technological steps (speed up the process of structural design prototype production as well as the phases of mass production), but also to achieve improved or new functional properties. For one-piece production up to 50% of the price of a single component can be saved in comparison with conventional technologies. The possibility of manufacturing hollow products brings weight and material savings, which is key for example for transportation. A whole number of additive technologies are currently in development. Multi-material 3D printing using the technology of selective laser melting (SLM) or DMLS (direct metal laser sintering) opens up further possibilities when joining two or more materials, combining their physical and functional properties. Further powder-based additive material depository technologies for metal materials such as direct laser deposition (DMLD, PB DED) and laser powder bed (LPB) or technologies with wire additive materials (WAAM), allowing for the integration of collaborative robotics into the production process. One promising direction of these activities is the utilisation of a combination of additively produced parts and cold kinetic deposition (cold spraying – CS), bringing benefits in the form of unique mechanical and physical component properties. Additive technologies are widely used not only in the production of new parts, but also for the repair of parts being operated. Additive manufacturing and the associated processes are disruptive and innovative technologies that are surpassing and pushing out our current technology. They are finding uses in almost all branches of industry from human health to the aerospace industry. Changes in industrial production are not the only issue here, but above all an understanding of the principles of additive manufacturing.
Competencies and provided expertise in the field:
- Technologies of selective laser melting (SLM) for the production of components and parts with complicated and structured geometry with the use of one or more material parts.
- Robotised powder deposition processes not only on flat, but also curved surfaces or rotating surfaces (the technology of cold kinetic deposition for surface treatment of components and parts).
- The design of complex bimetallic components with a sophisticated structured architecture.
- Study of the microstructure of additively manufactured parts and the microstructure of metal material interfaces.
- Research into the mechanical properties of the interfaces of two metal alloys, including an evaluation of fatigue behaviour.
- Influencing material properties using heat treatment as well as surface treatment methods (including the use of electron beams).
- Electromagnetic properties of alloys, internal material attenuation and energy absorption, modification of surface friction.
- Targeted modification of the electromagnetic behaviour of components. Use in the creation of thermal barriers.
- Development of parts using energy absorption materials. Development of multi-material 3D printing in the field of vibration absorption. Development of products for biological applications.
- Deposition of functionally graduated multi-material components with higher deposition speeds and larger volumes (350 × 450 × 600 mm) using DED technologies.
- Deposition on metal parts with the sensitive resolution of laser powder bed (LPD) technologies).
- Testing of a wide range of deposition material combinations.
- Deposition of entirely unique materials thanks to the ability to combine powders during deposition and the utilisation of in situ nanoparticle production.
- Development and experimental production of larger components using combined DED and LPB deposition.
- Accompanying microstructure, fractographic analyses, thermophysical measurements, software for the shape optimisation of parts. Use of the “contour cut method” to measure residual stresses.
- Characterisation of mechanical properties is possible with the miniature sample method.
- Structural designs taking into account topological optimisation, designs of light bionic metal structures including digital validation and finite method simulation, conformal cooling designs, internal miniature lattice structures.
- Research into the significance of individual process parameters influencing the printing process and their impact on the resulting shape, surface integrity, surface treatment and production precision of the part manufactured from powdered metal and a simulation of the process of additive manufacturing in a virtual environment using special software and taking into account residual stresses.
- Studying thermal effects and their influence on the mechanical, physical and chemical properties of manufactured parts with a focus on heat treatment.
- Development of new progressive trends in finishing, surface treatment and inspection of material structures, evaluation of surface integrity, surface layers and experimental measurement.
- Geometric (micro and macro geometry) and material designs of cutting tools and choice of appropriate cutting conditions to ensure the correct properties of machined surfaces.
- Analysis of chosen parameters of surface integrity – determination of the micro geometry of the surface, analysis of surface and sub-surface layers, analysis of residual stresses.
- Evaluation of the influence of the manufacturing technologies and process conditions used on surface quality.
- Evaluation of the quality of surface and sub-surface layers after the application of machining with high cutting speeds and feed rates (HSC and HFC technologies).
- Evaluation of micro and macro geometric characteristics of surfaces, structural and physicochemical changes in the surface layer, the degree, depth and character of surface and sub-surface layer hardening, the importance, size and progress of sub-surface residual stresses.
Advanced manufacturing systems including additive manufacturing
From a production technology development standpoint, the important thing is complex production technology design from intermediate products made by casting, welding or additive technologies, to the resulting machining of parts to their final specifications with possible surface modifications, including quality control and robotic manipulation. Development of the conventional or additive manufacturing technologies themselves is key (PTA, WAAM, DMLS). Increased attention must be given to post-production, due to the need for sufficient precision and desired characteristics. This leads to a need to develop knowledge of highly-precise machining and finishing including the necessity of finishing difficult-to-machine materials created for example using plasma cladding technology. A key issue is the modification and evaluation of surface integrity depending on the additive technology used. One prospective method is to use the physical effects of kinetic doping for the modification of surface properties and methods for the evaluation of the propagation of residual stresses in the surface layer via the method of continuous electrochemical etching. Further, also laser micro-machining and structuring of hard and superhard materials in order to change the functional properties of machine tools. Ensuring the development of all component technologies concerning the quality of the final product is only possible with new findings and knowledge in the area of quality control using coordinate measuring machines, computed tomography or surface integrity assessments. It is appropriate to provide a complex description of the physical behaviour of the machine during the process of machining, which is capable of virtually testing, predicting and optimising the machined results, including precision and quality of the machined surfaces before the technology is transferred to the machine itself (incl. virtual modelling of additive processes).
Competencies and provided expertise in the field:
- Development of advanced production processes, the design of complex manufacturing systems integrating conventional and additive technologies.
- Experimental manipulation options with individual production processes from intermediate goods to final surface treatment, in order to design a competitive manufacturing system.
- Development of deposition processes of high-melting materials on a substrate material with the goal for example of increasing the abrasion-resistance of parts or even to create self-supporting 3D welds using the PTA method.
- Tests of electrode wear, tuning of welding processes for new material combinations. Study of the influence of new surface treatments on the welding process including difficult-to-weld reactive materials, such as Al alloys.
- Research and development of new technological processes for additive and hybrid technologies on a WAAM basis with working dimensions up to 350 × 200 × 200 mm.
- Development of process parameters for printing using DMLS technologies (laser speed, spot size, overlap of individual tracks, laser energy and more) for a given powder material with optimisation criteria such as maximum productivity, minimal porosity, surface quality, mechanical properties.
- Machining of difficult-to-machine materials such as titanium, nickel and cobalt alloys and ceramics.
- Precise machining of parts and surface finishing with high demands on surface quality for example for parts made with additive technologies.
- Integration of robotic manipulation of difficult objects machining robots.
- Laser micro-machining and structuring of hard and superhard materials in order to change their functional properties (micro-machining of diamonds or polycrystalline boron nitride for machine tool applications).
- Research of processes for the removal of thin protective coatings on moulds and cutting tools.
- Changes in the surface properties of materials concerning tribology, wettability, biocompatibility, chemical and optical properties.
- Research into the physical effects of kinetic doping to modify surface properties of parts (research into microstructural changes and the development of surface alloys, study of the impacts of heat on the microstructural development of kinetically enriched metastable surfaces, dopant solubility in crystalline and amorphous substances, defects in the oversaturated crystalline lattice for surface functionalisation, microstructural ion-beam assisted development of surface films).
- Modification of surface properties, surface structure topography and design, modification of films and their adhesion for the functional elements of bone grafts, ceramic segments, corrosion resistance of silver surfaces, battery cell electrodes.
- Identification of any sources of unsatisfactory quality in the end-result of the machining and virtual testing of the influence and optimisation of process parameter settings, control parameters and machine properties, improves quality and precision of the machined surfaces.
- Optimisation of strategies for machining and path control to maximise the efficiency and productivity of the machining.
- Analysis of the influence of malleability and dynamic properties of the machine, tool and workpiece, machining quality and productivity.
Mechatronics, smart components, NVH
Smart machines are the answer to the demand for increases in operational and production efficiency, will be less taxing on natural resources (both materials and energy), including their impacts on the human body. A crucial focus of research is on the methods and processes of computational analyses, the design and use of smart materials, structures, control, electronics and electrical engineering, information technology, artificial intelligence for predictive maintenance (virtual twins, models), vibro-acoustic diagnostics (NVH). Above all, integrating multiple technologies into a single innovative smart machine part unit can save operational and material costs and reduces impact on the human body. Mechatronic components and applications are commonly used in a number of industries, not only in machinery. Vibro-acoustic output is an integral part of each machine in a number of areas of industry, with the manufacturing, automotive, aerospace and consumer goods industries dominating.
Competencies and provided expertise in the field:
- Research in the field of smart solutions for mechatronic systems and technological processes.
- Research into integrated mechanical parts, actuators and driving mechanisms, including control, electronics and sensor systems.
- Research into energy harvesting devices for autonomous powering of wireless monitoring, diagnostic and reporting systems.
- Methods of modelling and the development of algorithms and programs for the effective calculation of nonlinear multidisciplinary problems in the production process and their following implementation in machine units.
- Methods to increase geometric, operational and production precision using volumetric compensation of the production machine.
- Research into methods of use of virtual / digital twins for machine parts, units and devices.
- Research and development of virtual twin methods for the evaluation of the behaviour of machine tools influenced by heat and the malleability of materials; designing new compensation methods.
- Research into piezoelectric composite and polymer materials for reliable technological integration into machine parts.
- Research in the area of smart materials, primarily nanotechnologies with applications in nanomechanics; interpreting the mechanical response of nano-objects (for example nanotubes, nano-aggregates) in smart materials with the possibility of introducing internal material scaling.
- Research into advanced methods (including artificial intelligence) for the testing, diagnostics and predictive maintenance of production machinery, as well as other aerospace, transport and energy technologies.
- Development of finite fracture mechanics methods in the area of mesomechanics, allowing for the evaluation of both the initiation of the cracks themselves on the surface of smart (or generally fragile) materials, where stress states occur at the edge of the strength of a given material, but also the description of fragile fracture initiation in existing stress concentrators.
- Visualisation of the processes of preparation and execution of production, the state of machinery, operating processes, ergonomic studies and the evaluation of machinery safety.
- Research and development of machines and complex machine devices from an NVH perspective (determination of the layout of acoustic pressure areas in direct proximity to critical points for sound emission from structures, wavefront shapes in the surroundings of the measured objects, the direction and means of propagation within open sound fields, establishment of energy balance of forced structure oscillations and transmission to acoustic cavities).
- Research and development into NVH reduction for large machines, devices and systems.
- Research and development of processes ensuring the effectiveness / stability / appropriateness of production processes.
- Determination of the layout of acoustic pressure areas in direct proximity to critical points for sound emission from structures, wavefront shapes in the surroundings of the measured objects, the direction and means of propagation within open sound fields, establishment of energy balance of forced structure oscillations and transmission to acoustic cavities.
- Complex measurements and verification of material properties and mechatronic systems in machinery, for example in production processes, adjustment of materials or technical diagnostics of device condition. Study of the methods of parameter quantification of machined surface integrity, depending on manufacturing technology.
Manufacturing technologies of nanofibrous structures
Nanofibres are characterised by a high specific surface area due to their very small diameter from tens of nanometres to a micrometre. Due to these properties, nanofibrous layers are used not only in technical applications (filters, sensors, battery separators), but also in medicine (surgical nanothreads, the preparation of artificial organs, blood vessel transplants, targeted delivery of medicines) or are being developed for these applications. The base materials for the preparation of nanofibres are synthetic or natural polymers, usually in the form of a polymer solution or melt. The production of nanofibres is based on unique principles, and there are currently several methods for the replicable and industrial preparation of nanofibrous layers with the required parameters. This technology uses electrostatic spinning from the free surface of polymer solutions (DC electrospinning) to create nanofibres. Another option for the production of nanofibres is to use an alternating electric field (AC electrospinning) or to spin fibres using centrifugal forces (forcespinning). New and unique laboratory spinning devices and experimental production lines are being developed for the abovementioned methods of nanofibre production. These unique machines and devices allow for the subsequent development of new materials and products for various applications in filtration, air purifying and water treatment, special technical textiles, sorption materials and especially medical and bioengineering applications.
Competencies and provided expertise in the field:
- Development of spinners and research into new nanofibrous materials and structures, and the technology of their manufacture (research and development of new and variable manufacturing technologies of nanofibrous material, which is then processed in linear, surface and three-dimensional nanofibrous structures including structures combined with traditional textile fibres and structures).
- Development of mechatronic systems and control algorithms necessary for the production of nanofibrous structures.
- Research and development of spinning electrodes and heads.
- Research into the field of internationally novel methods of the production of nanofibres and nanofibrous structures including the industrial legal protection of these production processes.
- Theoretical and experimental analyses of the spinning process.
- Simulation of the intensity distribution of the electrostatic field and other phenomena during the spinning process.
- Simulation of yarn ballooning in the creation of linear nanostructures.
- Research into new nanomaterials and nanostructures.
- Research and development of technologies, new machinery and productions lines for the manufacture of linear, surface or spatial nanofibrous structures by the effects of electrical current and centrifugal forces.
- Research, development and optimisation of machine and device subsystems for the preparation of nanofibrous materials for biomedical, hygiene, filtration and other applications.
Complex production units
The variability of products from the chemical, food, pharmaceutical, processing and consumer goods industries dictate the requirements for unique structural and technological designs of sub-installations as well as whole production lines in a given area. Manufacturing processes in the chemical, food, pharmaceutical and associated industries including the commonly discussed biorefineries are however so complex, and include chemical reactions, that individual processes often cannot be tackled individually. For this reason, it is the necessary to study individual processes in model devices which correspond to the conceptual layout of the industrial process. Effective tools to meet the requirements for the technological makeup of a final product are above all the theoretical foundations of transport phenomena, in other words the transfer of momentum, heat and mass. By describing the machine / processed material interaction, a functional technical unit can be designed meeting all the parameters of production. Technological devices include a set of laboratory, sub-pilot and pilot plants, which can be assembled into functional units so as to make up a whole production unit or whole production line. Thanks to these devices, it is possible to define and verify operational parameter dependencies relating to the processing of the input (raw) material and to size the machines and devices at a smaller or larger scale. The understanding and description of these dependencies allows the implementation of modern processing technology and its transfer from the laboratory to an industrial scale. Eventually, this knowledge allows for the intensification of production and the optimisation of manufacturing by reducing production costs, improving safety of both the process and the product and increasing product quality.
Competencies and provided expertise in the field:
- Research into the field of machines and devices for the chemical, food and processing industries including modern technologies corresponding to the biorefinery concept.
- Design and verification of operational parameter dependencies on the processing of the input (raw) material and sizing of machines and devices at a large and small scale.
- Experimental research of hydrodynamics of single and multi-phase flow in equipment, the rheological and flow properties of liquids, suspensions and dispersions, viscoplastic and viscoelastic materials.
- Distribution of delay times, size and property distribution of the solid phase during hydraulic and mechanical processing.
- Heat transfer in single or multi-phase systems, heat transfer during boiling and condensation, the influence of the thermophysical properties of materials on their processing, phase transfer of substances.
- The kinetics of processes involving chemical reactions, gathering of dimensionless process characteristics of individual phenomena, mathematical modelling of processes and devices.
- New experimental methods in the area of multi-phase flow and contactless measurement of heat transfer.
- Defining the rules for upscaling processes and devices, establishing process parameters necessary for the design and construction of industrial machinery for the required manufacturing technology.
- Conceptual designs for unique devices for the transfer of momentum, heat and mass.
- Construction of individual pieces of equipment and devices, intensification and optimisation of processes and devices.
- Development of measuring methods and devices for specific industrial needs.