The NANOTUN3D workplan follows the main blocks towards the industrialisation of the nano-modified Ti alloy applications:
New material development: uniformly integrated NPs and matrix processability, as well as material morphology (spherical powder) are requirements. The approach selected is to disseminate NPs with a core-shell structure. The shell will interact with the matrix, while easing the subsequent powder metallurgy processes. WP1 will deal with the development of the different core-shell combinations and will analyze the most adequate ones. Some of these analyses will be fed back from WP3 and WP4, which will iterate in their first tasks during the first 14 months of project. WP1 will also provide core-shell batches for pilot development.
Raw material manufacturing processes: AM powder is manufactured by means of two main routes (EIGA and Gas Atomisation), and WP3 and WP4 will deal with these issues. The core-shells from WP1 will be integrated in the two processes. This testing will also be fed back to WP1 to improve composition and morphology of core-shells. WP3 and WP4 are designed to provide powder batches on the hundreds Kg.
AM scenarios (“inside and outside the machine”): Powder acceptance tests will be carried out. As an outcome, WP5 will only accept one of the powder production routes. This route will be extensively tested to reach optimal processing parameters both in SLM and EBM. There will be no “best” processing technology: “scenarios” (set of parameters and design rules) will be developed and will produce test specimens and demonstrator parts. “Outside of the machine” processes will be optimised for each of the technologies on WP6: machining, welding, heat treating, etc will be extensively characterised.
After melting processes: When the powder is melt the surface roughness is proportional to the powder particle size. Dimensional accuracy often requires machining processes after melting. Some internal stresses may also appear and in consequence geometry distortions. Stress relief treatment or annealing should then be needed. In addition, other intrinsic phenomenon to AM is some slight porosity in the melted material, which could affect fatigue behaviour. All these post-treatments after melting should be studied in WP6 for properly specifying the manufacturing plan of a part.
Value Chain integration: A series of demonstrators will be produced out of the new material in WP8. A technical and economic validation (feasibility study and Life Cycle Analysis) will be carried out. WP7 will deal with qualification of the whole workflow: extensive testing and characterising for core-shells, powder, AM, etc. On the other hand, nanomaterials handling must be completely assessed and managed. WP2 will evaluate risks and hazards, test all environments of the material workflow and define an HSE management system for each of the steps.
Finally, continuous interaction from and to the market is expected througout NANOTUN3D. An specific WP (WP9) is devoted to exploitation and dissemination, and a management role is specifically in charge of the market link (expansion manager).