AddGLEIS

What it is about

The project partners of the project “Development of additively manufactured lightweight structures for use in rail vehicles (AddGLEIS) are working on the further technological development of lightweight construction approaches for rail vehicles by applying combined additive manufacturing processes and highly automated robotics. The properties of additive manufacturing processes, such as geometric flexibility, shortening of the manufacturing chain and improved material utilization compared to conventional manufacturing processes, are used to address aspects of lightweight construction. Additive manufacturing makes it possible to manufacture weight-optimized components with topology-optimized designs, which are characterized by load-bearing structures that correspond to the actual load curves and load sizes in rail vehicles. As a result, local underloads, as they occur in conventional structures due to production-related constant profile cross-sections and sheet thicknesses, can be greatly reduced and significant weight reductions can be achieved. A combined process chain of the AM processes Cold Spray (CS), Fused Granular Fabrication (FGF) and Wire Arc Spraying (WAS) is used to manufacture the load-optimized, organically shaped structures. In combination with high-performance robotics and a control system regulated by AI algorithms, highly automated additive manufacturing of complex component designs is made possible, which is not subject to the restrictions of conventional manufacturing processes.

Aims of the research project

The robot-based system to be developed should make it possible to fully automate the additive manufacturing process of topology-optimized lightweight structures using imaging sensors as a data source for the neural network of an AI algorithm. This makes available an additive process combination of cold spray, fused granular fabrication, and wire arc spraying that enables large-volume components to be produced safely and repeatably. By integrating the respective processes into an intelligent robotics system with special path planning and control, the ambitious goals of the project will be achievable. The combination of the additive processes mentioned above is to be considered innovative, as it enables the realization of composite structures according to the sandwich principle. Complex geometries such as hollow bodies or undercuts are achieved by applying plastic foams by means of fused granular fabrication, which are subsequently coated (metallized) with a metallic layer by wire arc spraying. The resulting substrate base is then coated with the load-bearing additive structure using the Cold Spray process. AI-based automated quality assurance also ensures that the generated component meets the geometric requirements, resulting in a further increase in the degree of automation of the overall system.

Motivation

Energy-efficient action is becoming increasingly important in all areas of the economy. In the field of mobility, especially in rail transport, lightweight construction is of particular importance in order to significantly reduce energy consumption in both passenger and freight transport.