FatDED

Zero defect manufacturing and predictive design of DED-arc components for demanding fatigue applications

Problem 1: Most of the literature concerning structural components produced using DED-arc processes give attention to their limitations due to “defects”

Solution 1: Change the dialog toward zero-defect manufacturing. For example, in welded constructions focus is given to imperfections and irregularities that only become defects if they exceed a pre-defined limit based on some performance standard.

Problem 2: Standardized surface roughness measures are at the wrong scale for DED-arc components.

Solution 2: Develop the framework for defining and classifying imperfections in DED-arc components considering both waviness and roughness.

Problem 3: Industry cannot adopt DED-arc produced components without recognized design guidelines.

Solution 3: The project will develop a predictive fatigue assessment method which is consistent with the quality measures developed in the previous solution and synthesize the assessment method into an industry-relevant fatigue design guideline compatible with International Institute of Welding recommendations.

Problem 4: Industry cannot adopt DED-arc produced components without components qualification protocols.

Solution 4: The project will define a pathway towards component qualification including:

•documentation of the consumables and manufacturing process,

•quality measures during manufacturing and the completed component,

•structural performance computations based on the developed protocols and, verification test results.