IRT JULES VERNE, one of the INTEGRADDE partners, is a French R&D an institute dedicated to advanced manufacturing technologies, based in Nantes., Crucial to the Loire Valley Region’s economic strategies, the institute is driven by the industry needs on mid and long-term market trends.
IRT Jules Verne embraces the industrial, scientific and technological challenges that concern five strategic industries: aeronautics, shipbuilding, automotive, energy and advanced manufacturing equipment.
It aims at boosting industrialization and bringing innovation to the factory floor by providing solutions to the technological challenges facing industrial segments, e.g. the design and implementation of advanced breakthrough technologies for manufacturing and production engineering. Its research programmes focus on three major areas of development:
- integrated product/process design
- innovative processes
- adaptive and smart manufacturing systems
IRT Jules Verne develops industrial technologies for its partners in the industry. It enables them to increase their competitiveness in their respective markets by innovating on five axes: forming and preforming processes, assembly, additive manufacturing processes, mobility in the industrial environment and manufacturing flexibility... Additive Manufacturing (AM) is one of the core thematic in the road map of IRT Jules Verne, in this field has been developing projects for its members and improving its infrastructure since 2012. Some of the JULES main activities concerns so far: The development of criteria adapted to the fatigue behaviour and dimensioning of parts manufactured by
- AM technologies, and the optimization of performance with enhanced AM processes.
- The evaluation of different AM technologies, metal and composite (for instance, WAAM, SLM, SLS and FFF).
- The study, characterization and modelling of welding by innovative approaches, and the development of WAAM (Wire Arc Additive Manufacturing) process of metal complex form assembling by robotized welding process to produce large parts.
To develop its research and innovation activities in AM, JULES has several key partnerships with industries, SMEs, RTOs and academic institutions like CNRS, École Centrale de Nantes, Université du Maine, etc.
The role of IRT JULES VERNE in INTEGRADDE
In INTEGRADDE, IRT Jules Verne leads the Multi-physics process simulation and modelling of DED processes supports NDT characterization programs developing Active Infrared Thermography technic and is the RTO follower of the Loiretech Pilot Line.
As RTO follower, IRT Jules Verne supports and assists Loiretech in the deployment of a hybrid manufacturing pilot line for INVAR panel mouldings developing extensive multiscale computer process modelling and critical tests to build the most effective sequence to minimize total part distortion and quality.
When considering the activity of the IRT Jules Verne in the field of NDT, Active Infrared Thermography appears to be a promising technic suitable for in-line monitoring because contactless and fast. Pulsed Thermography has demonstrated good reliability for surface porosities detection, surface cracks detection, AM deposition spalling and thickness variation when compared with other conventional NDT approaches.
AM processes require a multi-physics and multi-scale modelling approach addressing a large span of length scale starting from powder particle size (µm) to component size (m). Powder scale models (micro-scale) are utilized to analyze the nozzle behaviour including shield gas and carrier gas flows. Moreover, the powder focus is studied numerically to assess how the gas flow rates might be used to vary the powder focus size. On the other hand, when considering Wire Additive Manufacturing technics, specific attention has to be paid to the modelling of the melt pool considering, in particular, the arc heat source, temperature-dependent material properties and couplings between physics. Results of the melting models are compared with measurements performed and then used to provide required details to larger-scale models (macro-scale) focusing on workpiece distortion and residual stress assessment.
In addition, an efficient thermal model is used to manage the workpiece thermal history. Also, all thermal and mechanical and structural calculations are computed taking into account the effect of multi-passes AM. The machine control file is interfaced with the simulation tool. Results obtained will provide designers and process engineers information about possible hot spots and minimization of distortion based on an optimized manufacturing strategy.
The results of the research on multi-scale and multi-physics modelling led by JULES will be combined by INTEGRADDE with the research in other relevant fields, such as building strategy optimization, hardware-independent building process, online control, inline quality assurance or Data-Analytics in order to achieve the goal of developing a novel end-to-end solution capable of demonstrating the potential of Directed Energy Deposition (DED) processes for the manufacturing of certified large metal components in strategic metalworking sectors.