BALSAM · Boosting the surface quality and geometric accuracy in laser additive manufacturing via a novel data-driven control system design

Boosting the surface quality and geometric accuracy in laser additive manufacturing via a novel data-driven control system design

The BALSAM project (Boosting Accuracy of Laser Additive Manufacturing) is designed to address critical challenges in the field of Laser Wire-Feed Metal Additive Manufacturing (LAM), particularly focusing on enhancing surface quality and geometric accuracy. Conducted at the University of Luxembourg (UL) with collaboration from the Fraunhofer Institute for Production Technology (F-IPT), this project aims to leverage expertise across borders to advance LAM technology. Laser Wire-Feed Metal Additive Manufacturing is an emerging technology with immense potential in modern manufacturing, offering flexibility and customization in producing complex geometries. However, several technical challenges hinder its broader industrial adoption, including issues related to surface quality, geometric accuracy, and defects such as porosity, voids, and cracks. These defects often arise from factors like raw material contamination, process instability, and environmental disturbances, which necessitate automation and process control improvements. The BALSAM project recognizes these challenges and seeks to provide innovative solutions through a multidisciplinary approach. By integrating advanced sensing, control systems, and data-driven methodologies, the project aims to significantly improve the quality and reliability of LAM processes. This initiative is especially relevant given the strategic importance of LAM in enhancing the competitiveness and sustainability of manufacturing industries in Europe. The BALSAM project is structured around several key objectives aimed at overcoming the identified limitations in LAM: 1. Develop a Monitoring System: Create an advanced system for real-time data collection and fault detection during the LAM process. 2. Design a Novel Control System: Develop an innovative control system that enhances surface quality and geometric accuracy by integrating sensor-based feedback mechanisms into the LAM process. 3. Prototype Implementation: Implement the designed control system in a prototype to conduct experiments and validate its performance in real-time operations, ensuring practical applicability and effectiveness. 4. Research Management and Training: Promote knowledge transfer through education activities, including course training and dissemination of results, to build expertise and foster innovation in LAM. The BALSAM project is strategically positioned to enhance cross-border cooperation and foster a network of excellence in LAM. By partnering with leading institutions like UL and F-IPT, the project aims to pool advanced R&D capabilities in welding, metallurgy, robotics, and simulation. This collaboration is expected to strengthen Europe’s leadership in metal additive manufacturing and create a foundation for long-term research and development. Scientific and Technological Advancements: The project will contribute to the scientific community by addressing complex challenges in process monitoring and control systems for LAM. Results will be disseminated through publications in open-access journals and presentations at international conferences, enhancing the visibility and impact of the research. Industrial Adoption and Economic Benefits: By improving the quality and reliability of LAM-produced parts, BALSAM is expected to increase the adoption of LAM in European industries, leading to cost efficiency and reduced raw material usage. This aligns with goals for environmental sustainability and economic competitiveness. On the other hand, the integration of social sciences and humanities plays a crucial role in understanding the broader implications of LAM technology adoption. The BALSAM project considers factors such as workforce adaptation, ethical considerations in automation, and the socioeconomic impacts of technological advancements. By addressing these aspects, the project aims to ensure that technological progress aligns with societal needs and values. To maximize the impact of its findings, the BALSAM project will engage stakeholders from academia, industry, and government through various channels: • Workshops and Special Events: Engage with industry stakeholders and production clusters through workshops and events, such as DIH ON TOUR, to promote knowledge exchange and collaboration. • National and International Symposia: Participate in symposia on LAM and robotics, like the Lasers in Manufacturing – LIM conference, to share insights and foster dialogue among researchers and practitioners. • Publications and Conferences: Publish research findings in prestigious journals and present at international conferences, ensuring wide dissemination and integration of results into ongoing research efforts. Finally, the BALSAM project aims to make significant strides in improving the accuracy and reliability of Laser Wire-Feed Metal Additive Manufacturing. By addressing key technical challenges and fostering cross-disciplinary collaboration, the project is poised to enhance the competitiveness of European industries and contribute to sustainable manufacturing practices. Through its strategic focus and comprehensive dissemination efforts, BALSAM will pave the way for future research and innovation in the field of additive manufacturing.

Data: CORDIS, © European Union