Aluminium Additive Manufacturing

Sustainable Aluminium additive Manufacturing fOr high performance Applications

SAMOA aims to upscale the process chain of raw aluminium alloys from material efficient powder production, energy efficient laser and arc wire additive manufacturing to material recycling in order to reduce material need of up to 50%. New high strength aluminium alloys with reduced Si content, increased material strength and processable will be developed. The performance and sustainability will be shown in a demonstrative processing chain.

The SAMOA project started in April 2019 and will continue for three years.

The SAMOA partners are:

Luleå University of Technology

Politecnico di Milano

Fraunhofer IWS

IMR metal powder technologies

Gemmate

Centro Ricerche FIAT

Siemens AG

LTU Business AB


News

05/2021 SAMOA together with SPAcEMAN organized the seminar MAMAS on May 26th. More than 80 participants were registered and discussed the newest results of the projects. The recorded videos can be found here:

10/2020 Seminar about SAMOA and SPAcEMAN results

Results and findings from the EIT RawMaterials projects SAMOA and SPAcEMAN were presented in the AM-Seminar organized by LTU. High interest of more than 30 participants from several European countries was seen. Thank you all for your contributions.

10/2020 Project meeting online

The full consortium project meeting took place online again due to the travel restrictions. However, the partners were well motivated and significant progress was made. High Zr-contents were able to avoid cracking in LPBF. The designs for the final demonstrator parts were discussed and first demonstrator structures were already built.

04/2020 Project meeting online

Unfortunately, we could not meet in person as planned at our partner IMR in Austria this time. However, an efficient online meeting was possible, where all partners could share their recent findings and discuss.

03/2020 Powder development

The consortium finished the calculations and development of a new aluminium powder alloy that promises reduced crack susceptibility at high strength. Powder production will soon start at IMR.

01/2020 Wire-Arc-Additive Manufacturing (WAAM)

Siemens installed a new industrial setup for WAAM in Munich, Germany. Along, a digital twin for path planning was developed. First tests of building demonstrator parts are in progress.

11/2019 Project meeting in Milano

The very constructive project meeting was conducted at Politecnico di Milano. Actual results were shared and the next steps were defined.

08/2019 Powder produced

The first milestone was reached. IMR produced the powder that will be used for the Additive Manufacturing at PoliMi (powder-bed), IWS (blown-powder) and Siemens (filled wires).

04/2019 Kick-off meeting

Representatives from all SAMOA partners met in Luleå to get to know each other and to discuss the project tasks and timeline. Fruitful discussions initiated a smooth and motivated start into the project.


Work packages

SAMOA aims to upscale Additive Processes and recycling methods to make aluminium powders and Additive Processing technologies including powder recycling available for the market. The objective of the SAMOA project is to upscale

  1. the use of aluminium alloys and the development of diverse aluminium alloys for AM processes (IMR),
  2. the powder-based aluminium AM processes including powder‑recycling methods (PoliMi, IWS, CRF),
  3. the arc-wire AM processes (Siemens) and
  4. direct recycling methods of “waste” material (LTU) from research to market.


Events

Online workshop on AM

The workshop/seminar on Additive Manufacturing with a special focus on the EIT RawMaterials projects SAMOA and SPAcEMAN will take place October 27th-28th 2020. The access to the online workshop is free of charge. The seminar will contain introductions into AM, a design workshop, Cyberlab showing how to use a LPBF machine for metal 3D-printing and many presentations about ongoing research. Please just register with jorg.volpp@ltu.se.

AM-workshop

The workshop “Arctic Platform for Additive Manufacturing” will take place in Luleå October 24th-25th 2019 with the guest lecturer Prof. Frank Brückner (IWS, partner in the SAMOA project)

Presentation in Torino

Elena Lopez (IWS) and Tobias Kamps (Siemens) presented the SAMOA project on the Expert Forum Mobility in Torino, IT.

Project meeting

The next project meeting will take place in April 2021.

Publications

  • R. Casati “Design and heat treatment optimization of a novel high strength Al alloy for Selective Laser Melting” AAMS 2019, Goteborg, Sweden.
  • R. Casati “Design, manufacturing and characterization of high strength Al alloys with improved SLM processability” MAMC 2019, Örebro, Sweden.
  • M. Vedani, Presentation, EIT RawMaterials Expert Forum on Sustainable Materials for Future Mobility 2019, Turin, Italy.
  • E. Lopez, Presentation, EIT RawMaterials Expert Forum on Sustainable Materials for Future Mobility 2019, Turin, Italy.
  • T. Kamps, Presentation, EIT RawMaterials Expert Forum on Sustainable Materials for Future Mobility 2019, Turin, Italy.
  • J. Volpp, Journal publication, “Spattering effects during Selective Laser Melting”, Journal of Laser Applications
  • J. Volpp, H.S. Prasad, Conference publication, ”Impact of Powder Application on Particle Incorporation during Direct Metal Deposition”, Proceedings of LAMP2019 – the 8th International Congress on Laser Advanced Materials Processing
  • J. Volpp, Conference publication, ”Layer Geometry depending on number of tracks during Selective Laser Melting”, Lasers in Manufacturing Conference 2019
  • J. Volpp, Conference publication, “Powder particle movement during Powder Bed Fusion”, 17th Nordic Laser Material Processing Conference (NOLAMP17), 27 – 29 August 2019
  • A. daSilva, Conference presentation, “Additive manufacturing of aluminum: a review”, NOLAMP 17 • the 17th Nordic Laser Material Processing Conference
  • J. Volpp, Conference publication, “Early-stage development of analytical thinking in problem-solving tasks”, 7:e Utvecklingskonferensen för Sveriges ingenjörsutbildningar, Luleå tekniska universitet, 27 november – 28 november 2019
  • H.S. Prasad, F. Brueckner, J. Volpp, A.F.H. Kaplan, Journal publication, ”Laser Metal Deposition of copper on diverse metals using green laser sources”, The International Journal of Advanced Manufacturing Technology
  • J. Volpp, Workshop presentation, “Particle ejections during laser powder bed fusion”, IFSW Hirschegg workshop 2020
  • A. da Silva, Joerg Volpp, Jan Frostevarg, Alexander F.H. Kaplan ”Acceleration of metal drops in a laser beam”, (in publication process)
  • T. Hauser et al., Journal publication, ”Fluctuation effects in Wire Arc Additive Manufacturing of aluminium analysed by high-speed imaging” (in review)


Organization


Contact

Jörg Volpp

Luleå University of Technology

Department of Engineering
Sciences and Mathematics

SE-971 87 Luleå, Sweden

Phone: +46 920 493969

E-mail: Jorg.Volpp@ltu.se  Web: www.ltu.se