1. ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING TOPIC: AM for Metal Parts Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 Luis Portolés Head of Strategic Markets & Research Exploitation

2. PROJECT DESCRIPTION NANOTUN3D will develop new improved nano-based materials for metal additive manufacturing and characterise their operative life cycle, from nanoparticles and raw metal powder to final parts. Improvements of 30% of the main mechanical properties. Nanomodified powder particles production with an adequate dispersion in a Ti matrix through a core-shell approach. AM processing of new powders (parameters development, design rules, and powder recycling strategies. EBM & SLM are considered. AM process specification including post-processes: thermal & mechanical AM implementation in regulated markets through AM qualification. HSE management system for the different steps of the manufacturing chain.

3. PROJECT DESCRIPTION

4. Exploitable results (ERs) ER 1 Nanoadditived Ti64 alloy with advanced properties and the manufacturing method (core-shell NPs production, nanomodified Ti6Al4V powder as feedstock; AM process parameters, post—processes and material/process qualification). ER2 Safe workflow of nanoadditived material (synthesis, scale up, powder processing and Additive manufacturing). ER3 Methodology for process parameter development of advanced metal materials (EBM/SLM).

5. ER 1: Nanoadditived Ti64 alloy with advanced properties and the manufacturing method > A feedstock (metal powder) for AM (EBM&SLM) based on a nanomodified Ti64 alloy with enhance structural performance vs. Standard alloy (tensile properties 30-40% better, fatigue and wear properties enhanced 20-30% with no weight penalty. New material manufacturing method (core-shell NPs production, nanomodified Ti6Al4V powder as feedstock; AM process parameters, post—processes and material/process qualification). > End-users who are looking for lightweight structural parts to purchase (tier 1 and 2 of the aero sector). Service providers (engineers, manufacturers, designers, engineering departments of OEMs, business consultants). Possible partners interested to implement the results in IT Design tools and process planning, to enhance the manufacturing method and/or to expand the results to other nanomodified metal alloys. > Nanomodified Ti6Al4V powder particles suitable to be processed by EBM & SLM: powder/process specification, process parameters setup, design for manufacturing, preliminary behavior results for material/process qualification.

6. Technological Readiness Level > The expected TRL at the end of the project would be between TRL5 and TRL6 depending on every specific issue of this result. Milestones in the TRL progression up to TRL9 To cooperate with end users for implementing the nanomodified Ti6Al4V and the processes specified into the supply chain for manufacturing aircraft and space components. Main technical challenges in this result Further developments based on the qualification results: core-shell NPs, powder particles manufacturing methods, process parameters, post-processes. Additional qualification tests required depending on the end user requirements. Standardization. Time to market (Mth/yr): The time to market of this result would be just at the end of the project (03/2019) ER 1: Nanoadditived Ti64 alloy with advanced properties and the manufacturing method

7. IPRs Have you protected or will you protect this result before disclosing it? The intention is to protect all the relevant results, especially those crucial for industrial business. How? Commercial agreements are considered: Consultancy Services; Knowledge Transfer Agreements; Development Agreements for other core-shell NPs embedded in other metal alloy matrix; licensing-manufacturing sales an distribution agreements; characterization and testing services; material supply; AM manufacturing and post- process supply. When? Along the project as part of the exploitation plan, a business model will be developed and the corresponding IPR strategy will be conducted. ER 1: Nanoadditived Ti64 alloy with advanced properties and the manufacturing method

8. > This result consists of the development and 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. > Any stakeholder around the valued stream of the nanomodified Ti6Al4V such as synthesis labs, core-shell NPs manufacturers, powder manufacturing and processing, additive manufactured component manufacturers, post-processes providers, and end- users for operating in a safe manner. > The assessment of the environmental and health risks associated with the use of NPs along the value stream and the NANOTUN3D HSE management system approach. ER 2: Safe workflow of nanoadditived material (synthesis, scale up, powder processing and Additive manufacturing)

9. Technological Readiness Level > The expected TRL at the end of the project would be TRL7. Milestones in the TRL progression up to TRL9 To qualify the NANOTUN3D HSE management system approach and to prove in an operational environment. Main technical challenges in this result To adequate the facilities of the stakeholders for processing properly the material in every state in a safe manner. Time to market (Mth/yr): The time to market would be at the end of the project (03/2019) ER 2: Safe workflow of nanoadditived material (synthesis, scale up, powder processing and Additive manufacturing)

10. IPRs Have you protected or will you protect this result before disclosing it? The intention is to protect all the relevant results, especially those crucial for industrial business. How? The preliminary idea is to provide consultancy services; knowledge transfer agreements; development agreements for other core-shell NPs embedded in other material matrix. When? Along the project as part of the exploitation plan, a business model will be developed and the corresponding IPR strategy will be conducted. ER 2: Safe workflow of nanoadditived material (synthesis, scale up, powder processing and Additive manufacturing)

11. > This result consists of the methodology for developing process parameters for processing advanced metal material by additive layer manufacturing techniques based on powder bed fusion, such as EBM and SLM. > Possible end users who requires advanced metal material properties or other metal materials with no process parameters settings developed and available for EBM and/or SLM. > Process parameters development expertise for other metal materials, not only nanomodified Ti6Al4V. Knowledge of Design for Manufacturing for the new metal material. Preliminary results for material data for behavior performance. Design rules and process planning. Material/Process specification for manufacturing parts with new metal material. Material/process qualification method developed of the new metal material additive manufactured. Powder metal material specifications for feedstock procurement. ER 3: Methodology for process parameter development of advanced metal materials (EBM/SLM).

12. Technological Readiness Level > The methodology of the process parameters for advanced metal materials processed by EBM and SLM would be TRL5. Milestones in the TRL progression up to TRL9 To cooperate with end users mainly and other stakeholders for implementing the new metal materials and the processes specified into the supply chain for manufacturing final parts. Main technical challenges in this result Further process parameters development based on the qualification results. Further process parameters optimisation for improving productivity and/or technical requirements. Additional qualification tests required depending on the end user requirements. Time to market (Mth/yr): The time to market of this result would be from now and after the end of the project (03/2019). ER 3: Methodology for process parameter development of advanced metal materials (EBM/SLM).

13. IPRs Have you protected or will you protect this result before disclosing it? The intention is to protect all the relevant results, especially those crucial for industrial business. How? The preliminary idea is to reach Development Agreements for adapting to different systems (SLM and EBM); and to sign Knowledge Transfer Agreements. These agreements would be discussed and established along the project execution and at the end. When? Along the project as part of the exploitation plan, a business model will be developed and the corresponding IPR strategy will be conducted. ER 3: Methodology for process parameter development of advanced metal materials (EBM/SLM).

14. Expressions of Interest US-QUESTEK: The aim of the project, the research and the potential exploitable results keep parallelism with NANOTUN3D: new metal alloys for AM with enhanced performance processed by AM (Al and Ti based), even the development of new high performance alloys tailored for AM processes. US-EXOVA: Results of NANOTUN3D could be implemented in the Design allowable database/handbook. Cooperation in testing and qualification protocols for material/processes. Surface finish research could be applied for new nanomodified Ti64. Machine hardware modification for working with low cost raw material.

15. Expressions of Interest US-NIU: The calorimetry technique could help to monitor the energy deposition and the heat transfer during AM process and then to reduce the lead time for process parameters development and for researching about the residual stresses phenomena. The acoustic emission could help for designing the powder deposition system for assuring a high quality powder bed and assessing the powder manufactured. SA-DEDREF: Results of NANOTUN3D could be implemented in the DED procedures for in-situ repair components produced with the new nanomodified Ti64. New nanomodified Ti64 particles development for using with DED.

16. Expressions of Interest SA-FORMING: Improved scanning strategies for minimum residual stresses and shape/dimensional could be applied for processing the new material developed in NANOTUN3D. New knowledge on nanomodified metal matrix materials could be applied for developing and manufacturing reconfigurable forming tools. SA-MEDAERO: The methodology for characterizing and qualifying new materials processed by AM and the post-processing treatments could be shared with NANOTUN3D and applied to new material.

17. Expressions of Interest MX-FRISA: Potential use of new material developed for wires manufacturing for the Laser Metal Deposition. Cooperation in to the working parameters development and characterization. MX-SISAMEX : Development of process parameters for manufacturing high electrical/thermal conductivity material processed by AM in a single part avoiding welding requirements. To use the new material for manufacturing spare parts.

18. Expressions of Interest EU-AMAZE : The use of new nanomodified Ti64, the process parameters, the characterization and the recyclability study in a new and large AM machine for producing parts with zero waste for these key applications. To implement the new methods for fixturing and finishing components made with the new material. To design for this new material/machine. To apply lattice designs to this new material. To apply the optimized AM factory to this new material. To develop new standards for this material processed by this way. To use the computational model of AM process developed for processing the new material.

19. Expressions of Interest EU-REProMag : The outcomes of NANOTUN3D could be applied for new Ni-based alloys, ferrites (magnetic material), and alloys with complicated microstructures. EU-RepAIR: The outcomes of NANOTUN3D could be applied for producing enhanced spare parts, repairing damaged ones. The material/process qualification could be implemented in the Quality Component for a MRO business. EU-BOREALIS: The new metal developed could be implemented in the new additive and subtractive manufacturing: powder specifications, process parameters, design for manufacturing, characterization and qualification.

20. Expressions of Interest EU-AATID : The outcomes of NANOTUN3D could be applied for new aircraft and space components which require high performance vs. low weight. In addition, new concept designs with complex geometries could be applied with this enhanced Ti based alloy. These results will be applied directly to SLM and EBM. The characterization will provide information for topology optimization.