Combining DISsimilar materials into functional large-scale and light-weight COmponents and structures

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SBFI

Projektnummer

23.00020

Projekttitel

Combining DISsimilar materials into functional large-scale and light-weight COmponents and structures

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Abstract (Englisch)	The DISCO2030 project aims to develop two innovative hybrid manufacturing methods for joining dissimilar metal-metal and metalpolymermaterials. Both proposed methods are underpinned by additive manufacturing (AM) technologies from the emerging technologyfamilies of Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). DISCO2030 combines the advantages of PBF and DEDto enable the manufacturing of multi-material lightweight, complex geometry components/structures that are able to operate in harshenvironments. The process is expected to achieve a =20% lead time reduction compared to state-of-the-art manufacturing processes (suchas die casting and brazing) and manufacture multi-material parts that have a 50% lower weight compared to reference products and a30% higher performance (achieved among others by graded materials). The three use-cases to be demonstrated in the project are of highrelevance to the EU economy and include a rocket engine, a marine engine and a cryogenic hydrogen tank for primary applications in theautomotive sector. All components manufactured using the novel DISCO hybrid manufacturing methods will be subjected to rigid testingaccording to the respective industry standards. DISCO2030 is expected to generate significant impact by paving the way for the creationof new dissimilar material joining and testing standards, strengthening the EU’s leadership in AM technologies and increasing the EU’sresilience against global supply chain disruptions. Finally, DISCO2030 will contribute to the reinvention of the European aerospace,marine and automotive sectors, ultimately providing EU citizens with better, more sustainable and cost-effective transportation.

Kategorie

Text

Abstract
(Englisch)

The DISCO2030 project aims to develop two innovative hybrid manufacturing methods for joining dissimilar metal-metal and metalpolymermaterials. Both proposed methods are underpinned by additive manufacturing (AM) technologies from the emerging technologyfamilies of Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). DISCO2030 combines the advantages of PBF and DEDto enable the manufacturing of multi-material lightweight, complex geometry components/structures that are able to operate in harshenvironments. The process is expected to achieve a =20% lead time reduction compared to state-of-the-art manufacturing processes (suchas die casting and brazing) and manufacture multi-material parts that have a 50% lower weight compared to reference products and a30% higher performance (achieved among others by graded materials). The three use-cases to be demonstrated in the project are of highrelevance to the EU economy and include a rocket engine, a marine engine and a cryogenic hydrogen tank for primary applications in theautomotive sector. All components manufactured using the novel DISCO hybrid manufacturing methods will be subjected to rigid testingaccording to the respective industry standards. DISCO2030 is expected to generate significant impact by paving the way for the creationof new dissimilar material joining and testing standards, strengthening the EU’s leadership in AM technologies and increasing the EU’sresilience against global supply chain disruptions. Finally, DISCO2030 will contribute to the reinvention of the European aerospace,marine and automotive sectors, ultimately providing EU citizens with better, more sustainable and cost-effective transportation.