Sample Parts
One aim of RAPOLAC was to validate the SMD process for use within aerospace. As part of this goal, it was necessary to benchmark the process against traditional manufacturing processes for a standard features aerospace component containing SMD features such as walls, bosses and flanges.
The pieces below are made from a Grade 5 Titanium alloy (Ti-6Al-4V), commonly used in aerospace. The welding parameters are those produced during RAPOLAC. They have been optimised for material properties at different thicknesses. Two parts were produced - the one on the left is a thick component which has been heat-treated and part-machined; the component on the right was deposited with a thinner wall and has had no futher processing.
A part containing several standard features (cylinders, regular polygons, flanges and bosses) was designed to show some of the differing SMD geometries which can be deposited and used to build up more complex parts. It also replicates a pre-RAPOLAC part for comparison purposes. It consists of a hollow cylindrical part whose central section is made up of a polygonal solid. This part has a flange and boss deposited onto the main body.
A hybrid part was designed to show the benefits of using SMD to add features to already existing parts or as a means of reducing the size of forgings / castings. In this case, hybrid refers to a hybrid manufacturing technique rather than the use of different materials. For this component, a flange and boss were to be added to a cast bar then machined to final shape.
The way in which the manufacture of these parts compares with traditional manufacturing methods in terms of cost and environmental impact has been evaluated as part of the project. For large parts, there is a significant reduction in raw material and energy use.
More information on RAPOLAC sample parts can be found in the final project report