Grade2XL – Functionally Graded Materials for Extra-Large Parts - M2i

Project Description

Key information
EU funding: € 7,91 Million
Total budget: € 9,75 Million
Duration: 48 months [March 2020 – Feb 2024]

Background: Grade2XL is a joint development programme aligning partners along the value chain to foster the rapid development of WAAM materials and process. Grade2XL will deliver multi-material products of superior quality and performance. The high printing rate of WAAM, combined with the ability to control material properties down to the nanoscale, will enable building strong and durable engineering structures.

The Grade2XL project, funded by the programme Horizon 2020, will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large structures ~1 to >10 m length. Grade2XL will strengthen Europe’s capacity to drive manufacturing innovation globally and withstand growing competition from Asia.

M2i is leading the Grade2XL consortium and has been carrying out the following tasks:

Project initiation: proposal coordination and writing, consortium building
(WP 1 Functional grading) Topology optimisation: Design tool for graded structures with minimum distortions
(WP 7 Dissemination and exploitation): Generic communication and support in organising a WAAM Roadshow
(WP 8 Project management): Main contact point with the European Commission, day-to-day management

Project Partners:

Stichting Materials Innovation Institute (M2i), The Netherlands – Lead Partner
Rotterdam Additive Manufacturing Fieldlab (RAMLAB), The Netherlands
Gent University, Belgium
Delft University of Technology, The Netherlands
Commissariat à l’énergie atomique et aux (CEA), France
Technical Univerrsity of Denmark, Denmark
voestalpine Böhler Welding, Germany
Valk Welding, The Netherlands
Air Products, Belgium
Lincoln Electric Europe, The Netherlands
Politechnika Wrocławska, Poland
Naval Group, France
Gorenje Orodjarna, Slovenia
Energie de France, France
Arrk Shapers, France
MAN Energy Solutions, Denmark
Ucosan (Villeroy&Boch), The Netherlands
GKN Aerospace Services Ltd, United Kingdom
Kuźnia Jawor S.A., Poland
Bureau Veritas, France
Pôle EMC2, France

Ambition:

Grade2XL will deliver a multi-material, high throughput WAAM system, removing the technological barriers that hinder the application of WAAM, on three levels:

Material level: functionally graded (multi)materials will be achieved by controlling the two main factors governing the material properties: the chemical composition and the thermal.
Process level: high WAAM productivity will be achieved using multiple wire deposition systems. The productivity will increase from typically 2 kg/h to 5 kg/h, which can double when a dual robot configuration is used. In-line contactless inspection will ensure first time right quality and facilitate qualification.
Life cycle or system level: challenging applications will demonstrate the lifecycle benefits of WAAM multi-material devices and in-line process control.