NANOTUN3D

The use of nanoparticles in 3D printing is progressing fast. Polymeric materials have benefited from the addition of carbon nanotubes or graphene to improve mechanical properties, conductivity and contribute to lightweighting; nano-charged inks have also been 3D-printed, opening possibilities to low-cost electronics and sensors. However, structural parts with key responsibilities (fatigue life, high temperature behaviour, dimensional accuracy, etc.) are still manufactured in metal. Although experiences in adding nanoparticles to metal powder for AM processing do exist, the industrialisation of the process (from powder batch volumes needed, handling and recycling protocols, to AM productivity and quality) is still underdefined. NANOTUN3D will deal with these shortcomings through an innovative concept that goes beyond the state of the art of the science and technology areas involved.

NANOTUN3D will take advantage of the possibilities of Additive Manufacturing (AM) together with the development of a specially tailored Ti-based nano-additived 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.).

Nanoadditivation will be optimised by means of an innovative core-shell treatment of the NPs that suits the Ti matrix and produces Ti64-like powder ready to be AM processed.

Two complete manufacturing routes will be developed 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.

Likewise, the process parameters settings, hardware modifications and powder reusability strategies needed for processing the new nanomodified Ti6Al4V by SLM and EBM (the most popular Metal AM technologies) will be defined.

But NANOTUN3D goes beyond the mere manufacturability of nano-modified Ti parts. The project will develop a complete qualification approach of material and transformation processes (including postprocesses such as machining, surface and heat treatments) along the full value stream, which can be extrapolated to new prospective materials following the same production concept.

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.

New material development: with uniformly integrated NPs (Improved metal base/NPs interaction working with “core-shell apporach”) in the Ti matrix, which would guarantee processability properties.

Raw material manufacturing processes: The ideally dispersed Nano-charged AM powder will be manufactured through two main industrial scale routes (EIGA and GA).

AM and postprocesses scenarios (“inside and outside the machine”): the manufacturing routes will be extensively tested to reach optimal parameters both in SLM and EBM, as well as in “outside of the machine” steps: machining, welding, heat treatments, etc

Value Chain integration: demonstrators will be validated technically and economically (feasibility study and Life Cycle Analysis). Qualification of the whole workflow with a view on aerospace applications will be dealt with. Risks and hazards will be identified and quantified, defining an HSE management system for each of the steps.

A sound consortium

The NANOTUN3D consortium has been built with excellence and delivery in mind. 9 partners from 6 countries, represent technical centers, raw material producers, transforming SMEs, and equipment manufacturers.

The structure of the NANOTUN3D consortium answers some key ideas in H2020:.

Technology complementarity and value chain coverage: The two topic disciplines (nanotechnology and AM) are fairly represented in the consortium, as is the life cycle of the material to be developed (both under a technical and management point of view).

TRL representation and execution: both TRL4 (Technology validation in laboratory) and TRL5 (validation in relevant environment) are covered by the roles of the different partners.

Exploitation oriented: technology, knowledge, technical servicing and production can be directly exploited by the consortium either internally or as future market opportunities.

NANOTUN3D will contribute to widening the applicability scope (new material, new applications) of AM metal technologies, where Europe is leader, while providing competitive advantage to European AM powder manufacturers (inclusion of radically new materials in their offer, knowledge development to process new nanoadditived materials, etc.,).

Users of the metal AM technologies will improve their innovation capacity, aiming at additional sectors/customers, being less limited by material choice. Opportunities will be opened to nanotechnology companies having access to the AM market.

The NANOTUN3D workflow will make possible the easy transferability to other nano-additived metallic powders. Additional areas such as AM standardization and nanosafety will also benefit of the workflow characterisation and management systems defined.

Project reference: 685952

Coordinator: ASOCIACION DE INVESTIGACION DE LAS INDUSTRIAS METALMECANICAS, AFINES Y CONEXAS Spain

Participants LAURENTIA TECHNOLOGIES SLL Spain ASOCIACION CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS Spain UNIVERSITAT POLITECNICA DE VALENCIA Spain ZOZ GMBH Germany TLS TECHNIK GMBH & CO. SPEZIALPULVER KG Germany APR SRL Italy VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK N.V. Belgium TWI LIMITED United Kingdom

European Comission Funded under: H2020-EU.2.1.2., H2020-EU.2.1.2.1., H2020-EU.2.1.2.2., H2020-EU.2.1.2.5.

• UE - Horizonte Europa (HE): Research and Innovation Actions (RIA)