"NANOTUN3D" NANOTUN3D - DEVELOPMENT OF THE COMPLETE WORKFLOW FOR PRODUCING AND USING A NOVEL NANOMODIFIED TI-BASED ALLOY FOR ADDITIVE MANUFACTURING IN SPECIAL APPLICATIONS DESCRIPTION NANONTUN3D will take advantage of the possibilities of Additive Manufacturing (AM) together with the development of a specially tailored Ti-based nano-aditived material to achieve dramatic improvements in structural parts of aero, space, mobility, and equipment sectors, reaching expected savings between 40% and 50% of material in critical applications. inherent benefits of AM will be kept (decrease in throughput times, tool-less production, high buy-to – fly-run ratios, etc.). By adding nano-particles (np) to metal matrixes, the whole life cycle of the NANOTUN3D material has been designed with AM processability in mind: safety and handling issues, processing in well-known AM technologies, postprocessing and eventual certification issues are dealt with , and innovative core-shell treatment of the nano-particles that suits the Ti matrix and produces Ti64-like powder ready to be AM processed. A whole Health, Safety and Environmental (HSE) management system will also be developed, as well as all the protocols to start qualification / certification of material and process. OBJECTIVES NANOTUN3D will: • Develop a raw material (metal powder) to be processed by additive manufacturing techniques with powder bed fusion –selective laser melting (SLM) and electron beam melting (EBM) - based on a nanomodified Ti6Al4V alloy with enhanced structural performance versus standard alloy (tensile properties 30-40% better; hardness, fatigue and wear properties enhanced 20-30%, and high temperature properties enhanced 15-25%, with no weight penalty). • Definition of a “core-shell” concept and process for embedding ceramic NPs in the Ti6Al4V matrix, improving the matrix / NP interaction in metal powder while reducing safety risks. • Development of the synthesis and manufacturing methods for producing the “core-shells” both in lab and industrial pilot scale. • Definition of two manufacturing routes for the NANOTUN3D material, based on the most popular powder manufacturing techniques: Gas atomization (GA) and EIGA. Both routes will be scaled up to produce powder batches on the hundreds Kg. o Re-design and simulate the gas injection system (DIE) for simultaneous powder and core-shells injection. o Develop mix / consolidation process towards a uniformly dispersed bar / ingot on the EIGA process • Development of the process parameters settings for processing the new nanomodified Ti6Al4V by SLM and EBM, as well as the hardware modifications needed. Targets in the optimization of process parameters will be the ones of the well-knownTi6Al4V. • Defines a reusability strategy of the NANOTUN3D powder for both SLM and EBM. • Assessment of postprocesses needed by the AM manufactured NANOTUN3D part: surface and heat treatments applied to improve roughness, fatigue behavior and to reduce residual stresses and distortions of the manufactured parts, as well as machining conditions. • Development of a qualification approach of material and transformation processes developed along the full value stream for the SLM and EBM processed NANOTUN3D material, which can be extrapolated to new prospective materials following the same production concept. • Implementation of a Health, Safety and Environmental (HSE) management system that will deal with the safety risks associated with the use of nanoparticles along the value stream, and will define a reliable workflow of the manufacturing, handling and processing of the Ti-based nano-additived material, from core-shell production to final part. • Validation of a supply chain for the NANOTUN3D workflow that can be extrapolated to other nano-composites increasing the range of products available in metal AM technologies. • Direct application of the new nanomofied Ti6Al4V processed by SLM and EBM, the production workflow and the HSE management system in two “virtual demonstrators” from the aero sector. Project Number: 21580004 Grant Agreement: GA-685952 Duration: From 01/10/2015 to 30/09/2019 Coordinated in AIDIMME by: PORTOLES GRIÑAN, LUIS R&D Line: ADDITIVE MANUFACTURE PUBLISHED NEWS general broadcast https://actualidad.aidimme.es/2022/01/04/nanotune3d-abc/ (...) https://www.abc.es/espana/comunidad-valenciana/abci-tecn (...) PROJECT WEB http://www.nanotun3d.eu PARTNERS AIDIMME - METAL-MECHANICAL TECHNOLOGICAL INSTITUTE, FURNITURE, WOOD, PACKAGING AND RELATED - COORDINATOR, UPV - VALENCIA POLYTECHNIC UNIVERSITY, CEIT TECHNOLOGY CENTER ASSOCIATION, LAURENTIA TECHNOLOGIES, SLL, TLS TECHNIK GMBH & CO. SPEZIALPULVER KG, ZOZ GMBH, APR SRL, VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK NV, TWI LIMITED, GRANT € 489.031,25 TARGET AUDIENCE AND IMPACT MEASUREMENT 3946 Access to the project website 219 Access to news published on own websites. Total Accesses: 4165 Objective Sectors by CNAE CNAE: 3030 - Aeronautical and space construction and its - Number of target companies: 9 (2 from the Valencian Community) TRACTOR COMPANIES Thanks to its support and signature of the "declaration of participation" the project has been funded. KAMAX, SA UNIPERSONAL SOCIETY COMPANIES DIFFUSION R&D PROJECTS They want to know first-hand the evolution of the project, and its progress to the final result. COMPANIES TRANSFER KNOWLEDGE They will implement technologies, develop strategies or look for new models based on the results.