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1.

TWI LIMITED

Development and verification of microstructure, residual stress and deformation simulation capability for additive free-form direct deposition using multiple superalloys

  • 739,375
  • United Kingdom
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Development and verification of microstructure, residual stress and deformation simulation capability for additive free-form direct deposition using multiple superalloys
Company Name TWI LIMITED
Funded By 38
Country United Kingdom , Western Europe
Project Value 739,375
Project Detail

SUPERMODEL will (1) develop a state-of-the-art microstructure evolution model for blown powder laser metal deposition processing and post-processing of multiple super alloys (including Inconel 718) that can predict grain sizes; orientation and texture; phase composition (including precipitation & particle size); and defect (pores and lack of fusion) distributions; (2) link the microstructure model to part-level (global) thermo-mechanical LMD process simulations to enable a direct coupling between continuum-scale stress-strain behaviour and the evolution of microstructural internal state variables; (3) validate the computational models through iterative, detailed and comprehensive experimental test programmes including in-line monitoring of melt pools, thermal transients, stresses and deformation; post-build, 3D scanning of part distortions; metallographic examination and CT scanning; and (4) demonstrate the predictive powder of the model on a complex part (curved substrate with angular features) incorporating two different superalloys with runtimes less than 5 days. This will be achieved through an ambitious numerical-experimental procedure leveraging design-of-experiments methodologies and iterative feedback between modelling activities and testing to develop a robust software system. SUPERMODEL contributes to the aims of the Clean Sky Engines ITD by providing experimental data and simulation tools that will enhance the reliability of additive manufacturing technology, thereby streamlining LMD part certification and qualification, minimises experimental trial-and-error along the way. SUPERMODEL will therefore make progress towards achieving the EC goal of moving from “Modelling-for-Industry” to “Modelling-by-Industry” which means shifting effort from laboratory- and RTO-centred activities to helping industry equip itself with advanced simulation tools.

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Company Name TWI LIMITED
Address Granta Park Great Abington Cb21 6al Cambridge
Web Site https://cordis.europa.eu/project/rcn/222571/factsheet/en

2.

EIDGENOSSISCHE MATERIALPRUFUNGS- UND FORSCHUNGSANSTALT

High Cycle Fatigue Cracking of Meso- and Micromechanical Testpieces of Aluminide Intermetallics, with in situ Nanoscale Strain Mapping

  • 191,149
  • Switzerland
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High Cycle Fatigue Cracking of Meso- and Micromechanical Testpieces of Aluminide Intermetallics, with in situ Nanoscale Strain Mapping
Company Name EIDGENOSSISCHE MATERIALPRUFUNGS- UND FORSCHUNGSANSTALT
Funded By 38
Country Switzerland , Western Europe
Project Value 191,149
Project Detail

The aim of FracTAlS is to increase the understanding of the deformation mechanisms leading to and mediating cracking in high cycle fatigue loading of lightweight, structural aluminide intermetallics, in order to better direct microstructural and alloy development. Such materials are highly desirable for many rotating and airborne engineering applications but often suffer from prohibitive brittleness, particularly in fatigue. The project applies a combination of nanoscale strain mapping techniques recently developed by the host institution, and by Dr. Edwards, on novel in-situ meso- and micro-mechanical fatigue testing setups, to study deformation behaviour upon fatigue loading. Currently, the European hub plays a central role in the research and development of advanced gamma titanium aluminide alloys, such as for improved processability, and the large-scale production of ?-TiAl components. However, no significant improvements have been made to the fatigue properties of the lightweight ?-TiAl alloys in the past few decades, effectively limiting their widespread application in higher volume industries where they could result in considerable increases in fuel efficiency. Similarly, Mg aluminides, such as the ?-Mg17Al12 phase, possess outstanding strength to weight properties; given sufficient improvements to their toughness and fatigue performance, they would be excellent candidates for structural components in future, more ecologically friendly, aero-propulsion technologies where the operational temperatures are lower than gas turbine engines (e.g. electric and hybrid-electric). This project is closely aligned with EU policy on climate action and sustainable development as it targets reduced emissions through reduced hydrocarbon fuel consumption; its success will serve to increase the European confidence and knowledge-base in these material systems and, through further interaction with European industry, the extent of their use.

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Company Name EIDGENOSSISCHE MATERIALPRUFUNGS- UND FORSCHUNGSANSTALT
Address Ueberlandstrasse 129 8600 Dubendorf
Web Site https://cordis.europa.eu/project/rcn/222176/factsheet/en

3.

AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS

Rational Design of Ceria-Supported Non-Noble Metal Nanoalloys as Catalysts for the Selective Direct Conversion of Methane to Methanol

  • 172,932
  • Spain
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Rational Design of Ceria-Supported Non-Noble Metal Nanoalloys as Catalysts for the Selective Direct Conversion of Methane to Methanol
Company Name AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS
Funded By 38
Country Spain , Western Europe
Project Value 172,932
Project Detail

Methane (CH4) is a potent greenhouse gas that can come from many sources, both natural and manmade. The low temperature direct route to converting methane to methanol (CH3OH) a key feedstock for the production of chemicals that can also fuel vehicles or be reformed to produce hydrogen has long been a holy grail. The efficient use of CH4 emissions require catalysts that can activate the first C-H bond while suppressing complete dehydrogenation and avoiding CO/CO2 formation. The potential benefit of finding non-expensive and efficient catalysts for directly converting methane to methanol (DMTM), using only molecular oxygen, and perhaps water, is significant and new catalysts are being sought. This project aims to the rational design of such catalysts based on non-noble metal nanoalloys/reducible oxide systems. There are key challenges to be addressed, namely, to improve reactants activation, to obtain an understanding of the reaction mechanism and to improve selectivity. Real powder catalysts are too complex to enable us to disentagle the effect of the nature of the metallic phase (composition, structure, nanoparticle size), the role of the oxidic support and of metal-support interactions, and the role of alloying and water in controlling selectivity. The strategy here consists of creating and investigating model systems, which include essential parts of the real ones, but can still be studied at the atomic level using state-of-the-art computational methodology in chemistry. Calculations will be performed in close collaboration with experimental work employing well-defined model systems as well as powders. The synergistic power of theory and experiment is crucial to design new or improved catalysts. Theory will not only be used to explain experimental data, but also for pre-screening the behavior of catalysts. The goal is to develop basic principles for the rational design and optimization of nano-structured catalysts for mitigating greenhouse gases.

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Company Name AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS
Address Calle Serrano 117 28006 Madrid
Web Site https://cordis.europa.eu/project/rcn/221885/factsheet/en

4.

FUNDACION IMDEA MATERIALES

Creating an Infrastructure for the Numerical Exploration of Metallurgical Alloys

  • 160,932
  • Spain
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Creating an Infrastructure for the Numerical Exploration of Metallurgical Alloys
Company Name FUNDACION IMDEA MATERIALES
Funded By 38
Country Spain , Western Europe
Project Value 160,932
Project Detail

Manufacturing has considerable economical, technological, and environmental importance at the global scale, impacting fields such as transportation, energy, safety, and healthcare. Materials innovation has long relied on costly and ineffective trial-and-error experiments. Meanwhile, computational routes face challenges due to the multidisciplinary and multiscale aspects of linking materials processing, microstructure, and ultimately properties. By building an infrastructure for computational exploration of alloys, this project will put together foundations for computational discovery of structural materials, e.g. by means of high throughput and machine learning methods, which could lastingly change the way we approach metallurgical innovation. The project will bring together two complementary sets of skills, with a researcher expert in linking materials processing to microstructures, and a supervisor expert in predicting the mechanical behavior of complex microstructures. While adding an essential piece of competence to the host institution, the project will support the growth of the candidate as he aims at building a world-class research group in Europe. He will also gain key skills in software development, and a number of management and transferable skills with the support of award-winning management and human resources personal (monitored through detailed plans for career development, data management, and exploitation, dissemination, and communication of results). The impact and reach of the action will be maximized. First, by openly distributing all major components of the computational framework. Then, with scientific publications in high-impact scientific journals, as well as a broad range of outreach activities in the form of publications in non-technical outlets, reach out events to young and non-technical audiences, while ensuring accessibility to the widest possible audience (e.g. through commitment to international accessibility standards).

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Company Name FUNDACION IMDEA MATERIALES
Address Calle Eric Kandel 2 Parque Cientifico Y Tecnologico Tecnogetafe 28906 Getafe
Web Site https://cordis.europa.eu/project/rcn/221635/factsheet/en

5.

Cranfield University

Investigating Corrosion in Supercritical Fluids

  • 282,727
  • United Kingdom
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Investigating Corrosion in Supercritical Fluids
Company Name Cranfield University
Funded By 107
Country United Kingdom , Western Europe
Project Value 282,727
Project Detail

This project proposes to study how turbine materials may fail in a new specialist energy production environment. The materials to be studied are superalloys, which are nickel- and cobalt-based alloys that can resist and work at high temperatures. These superalloys can be coated with thin ceramic layers, known as a thermal barrier coating (TBC), or metallic layers, to help protect them when they are in a high temperature environment. It is important to know how the materials respond because they may be used in a new type of power plant which will expose them to an environment which is very unusual. This power cycle burns a fuel to drive a turbine and generate electricity when there is demand. The fuel can be natural gas or a synthetic gas made from coal, biomass or waste meaning that fuel supply is secure and power can be dispatched when needed. Unlike current power cycles using combustion, only oxygen, rather than air, is present with the fuel meaning carbon dioxide (CO2) and steam are the main products. The steam can be condensed out, and the CO2 kept. The CO2 then flows past the turbine at such high temperatures and pressures that it enters a special condition where it is neither liquid nor gas and is called supercritical-CO2. This new type of power cycle has many potential advantages. As the superciritcal-CO2 is very dense, its very good at pushing the turbine, so the energy from burning the fuel has a high efficiency of conversion into electricity, meaning electricity may be cheaper. It also means the turbine can be very small compared to other power cycles, so the new power plant can fit into small parcels of land, and can be put next to existing industrial structures for localised power generation. Finally, because the CO2 from burning the fuel is captured to drive the turbine, it doesnt have to be released into the atmosphere where it may contribute to climate change. Instead this CO2 can be captured, transported and used or stored. CO2 can be captured at 99% purity; this is better than specialist plant trying to remove CO2 from other power cycles, which aim to have 90% CO2 purity. This means the cycle can help make low-CO2 power while other renewable energy sources and storage options are developed. However, in the supercritical-CO2 going through the turbine, there can be small amounts of chemical contaminants that can degrade the materials it is made from. As this power cycle recycles CO2 before transportation and use (it is a semi-closed system), these chemicals can build up in concentration. To make sure that the plant built lasts for a long time and that there are no unexpected interruptions to power generation, it is important to know whether the turbine materials can survive these conditions as the supercritical-CO2 is at very high temperatures and pressures. By investigating the reliability of these materials, we can contribute to the confidence in these new, cleaner energy production systems, driving investment in and the spread of these options, rather than other cycles which may give off more CO2. To meet this projects aim of understanding materials degradation in this contaminated supercritical-CO2 operating environment experimental research much be carried out. Superalloy and ceramic coated samples will be provided by industry (see letters of support). These will be exposed at high temperatures (metal samples at 800-1000 C; TBC samples at 1100 C to simulate the cooling gradient anticipated through the component under operational conditions), high pressures (300 bar) and with chemical contaminants (such as H2O, SOX and NOX). Different superalloys will be used to see how differences in their chemistry, manufacturing and internal microstructure alters their reaction with supercritical-CO2. After a thousand hours exposure the samples will be looked at using specialist microscopy techniques to see how much metal has been lost and if any changes have taken place with the internal structure.

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Company Name Cranfield University
Web Site https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/S028757/1

6.

University of Warwick

EPSRC Centre for Doctoral Training in Modelling of Heterogeneous Systems

  • 6 Million
  • United Kingdom
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EPSRC Centre for Doctoral Training in Modelling of Heterogeneous Systems
Company Name University of Warwick
Funded By 107
Country United Kingdom , Western Europe
Project Value 6 Million
Project Detail

HetSys students will develop and apply computational models for heterogeneous material systems, addressing three distinct but closely connected shortcomings in current modelling paradigms: (i) most material systems of scientific and technological interest are highly heterogeneous in structure, phases, and range of length- and time-scales, whereas the predominant modelling paradigms typically focus on limited scenarios; (ii) coupling of scales is typically ad hoc, thus lacking robust quantification of uncertainty propagation across scales, essential for reliable and applicable models; (iii) research software is often poorly maintained and hard to re-use, further slowing down progress. Overcoming these interdisciplinary challenges to unlock more efficient simulation-for-design capabilities has been hindered by outdated training approaches: the pathway followed by, for example, a theoretical physicist has been distinct from that of a materials engineer, with the resulting lack of a common language preventing synergy across disciplines. HetSys will transform this landscape by being the first CDT explicitly targeting modelling of heterogeneous systems required by industry and academia, with all models to be implemented in robust and reusable software that produces probabilistic error bars on all outputs using uncertainty quantification (UQ). Exemplar research challenges range from novel materials and devices exploiting multiscale physics and chemistry, high performance alloys, direct drive laser fusion, future medicine exploration, smart nanofluidic interfaces, and flow through heterogeneous rocks. HetSys mission is to train high-quality computational scientists who can develop and implement new methods for modelling complex and heterogeneous systems in collaboration with scientists and end-users. Working in a highly interdisciplinary context is challenging even for experienced researchers but especially for an isolated PhD student. Creating a cohesive, interdisciplinary cohort connected through a joint training programme with an existing vibrant cross-departmental research community will create a culture that significantly lowers the entrance barrier into this style of research. Our multidisciplinary approach aligns with the formation of UKRI and will help to address the productivity gap identified in the industrial strategy by targeting several challenges and national priority areas. As noted by Innovate UK/KTN: "Industry requires new insight into how [materials] behave and uniquely this proposal sets the understanding of how uncertainty propagates across scales as a central theme". These benefits are recognised by industry through HetSys strong support from 14 industrial project partners. We have also established bilateral links with 12 international partners who have identified the same urgent modelling challenges. The potential impact of the postgraduate training is affirmed by the career destinations of the 70 students who completed their studies with the 33 HetSys supervisors since 2012: 27 have proceeded into academic research (21 postdoctoral and 6 academic posts), 28 into careers in industrial R&D and the engineering industry, 4 into IT, 2 to consultancy, 6 into school teaching and 2 to finance. The strong absorptive capacity for graduates is recognised by project partners, e.g. AWE: "given the ever growing importance that computational modelling is acquiring in the UK and internationally, there will be significant competition for the number of doctoral level scientists and engineers that you are proposing to train". New paradigms in the study of heterogeneous materials are vital for both academic research and industry. Future impact at larger scales will be greatly increased if researchers can be trained to master a wide range of techniques and encapsulate them in well-designed software.

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Company Name University of Warwick
Web Site https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/S022848/1

7.

University of Sheffield

EPSRC and SFI Centre for Doctoral Training in Advanced Metallic Systems: Metallurgical Challenges for the Digital Manufacturing Environment

  • 5 Million
  • United Kingdom
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EPSRC and SFI Centre for Doctoral Training in Advanced Metallic Systems: Metallurgical Challenges for the Digital Manufacturing Environment
Company Name University of Sheffield
Funded By 107
Country United Kingdom , Western Europe
Project Value 5 Million
Project Detail

Metallic materials are indispensable to modern human life. From everyday items such as aluminium drinks cans, to advanced applications like jet engine turbine blades and the pressure vessels of nuclear reactors, the positive social impact of metals is difficult to overstate. Yet despite major advances in our understanding of the manufacture and properties of metals, significant challenges remain. Constructing the next generation of electric cars will require improved lightweight alloys and joining technologies. Development of fusion power plants, which will provide near-limitless carbon-free energy, will require the development of advanced alloy systems capable surviving the extreme environments found inside reactors. For the next generation of hypersonic air and space vehicles, we require propulsion systems capable of over Mach 5. Alloys will need to survive 1800 degrees Celsius, be made into complex shapes, and be joined without losing any of their properties. Overcoming these challenges by improving existing metallic materials, developing new ones, and adapting manufacturing methods, then the benefits will be substantial. Now is a particularly exciting time to be involved in metallurgical research and manufacturing. This is not only because of the kinds of compelling challenges specified above, but also because of the opportunities afforded by the emergence of new advanced manufacturing technologies. Innovative techniques such as 3D printing are enabling novel shapes and design concepts to be realised, whilst the latest solid-state processes allow for the design and production of bespoke alloys that cannot be made by conventional liquid casting techniques. Industry 4.0, or the fourth industrial revolution, provides opportunities to optimise emerging and established technologies through the use of material and process data and advanced computational techniques. In order to fully exploit these opportunities, we need to understand the complex relationships between the processing, structure, properties and performance of materials, and link these to the digital manufacturing environment. To deliver the factories of tomorrow, which will be critical to the future strength of UK plc and the wider economy, industry will require more specialists with a thorough understanding of metallic materials science and engineering. These metallurgists should also have the professional and technical leadership skills to exploit emerging computational and data-driven approaches, and be well versed in equality and diversity best practice, such that they can effect positive changes in workplace culture. The EPSRC Centre for Doctoral Training in Advanced Metallic Systems will help to deliver these specialists, currently in short supply, by recruiting and training cohorts of high level scientists and engineers. Through collaboration with industry, and a comprehensive training in fundamental materials science and computational methods, professional skills, and equality and diversity best practice, our graduates will be equipped to become future research leaders and captains of industry.

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Company Name University of Sheffield
Web Site https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/S022635/1

8.

SWEREA SICOMP AB

Process Simulation and Tool Compensation Methodology for High Temperature Composite Processes

  • 700,000
  • Sweden
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Process Simulation and Tool Compensation Methodology for High Temperature Composite Processes
Company Name SWEREA SICOMP AB
Funded By 38
Country Sweden , Western Europe
Project Value 700,000
Project Detail

Process Simulation and Tool Compensation Methodology for High Temperature Composite Processes. The overall objective of ProTHiC is to develop materials, manufacturing, tooling and processing simulations technologies that enables further exploitation of carbon fibre-reinforced composites in applications where the temperature requirements are exceeding 200°C where currently only titanium or super-alloys are being used. ProTHiC will place its main efforts to: - Develop and characterize polyimide resins tailored for processing with RTM - develop, adapt and when necessary modify state-of-the-art processing simulation methodologies (curing and mould filling) to also work for high temperature composites - Validate simulation methodologies by against experimental data obtained from manufacturing trials performed on sub-components with simplified geometry (e.g. L- and T-profiles) - Establish a simulation assisted tool design process that integrates processing simulation methodologies with methodologies for tool compensation - Demonstrate the above-mentioned technologies by manufacturing of a demonstrator component that is defined together with the topic manager.

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Company Name SWEREA SICOMP AB
Address Fibervaegen 2 - Oejebyn 941 26 Pitea
Web Site https://cordis.europa.eu/project/rcn/220454/factsheet/en

9.

MEMETIS GMBH

Modular fluidic platform with Shape Memory Alloy miniature valves to disrupt medical technology industry (memetis)

  • 71,429
  • Germany
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Modular fluidic platform with Shape Memory Alloy miniature valves to disrupt medical technology industry (memetis)
Company Name MEMETIS GMBH
Funded By 38
Country Germany , Western Europe
Project Value 71,429
Project Detail

Memetis is an award-winning innovative SME, spin-off from Institute of Microstructure Technology (IMT) / Karlsruhe Institute of Technology (KIT) that designs modular fluidic platforms using Shape Memory Alloy (SMA) miniature valves for user specific needs. It enables the realization of unprecedented fluidic platforms in terms of outer dimensions, functionality, integration density and power consumption. Uses of the technology range from laboratory based tools to commercial applications like medical diagnostics. Processes which are normally carried out in a lab can be miniaturized on a single chip and performed at the Point of Care/ Point of Need to enhance analysis, diagnostic efficiency and speed while reducing sample and reagent volumes. At the intersection of engineering, physics, chemistry, information technology, and biotechnology, memetis can revolutionize the way patients are diagnosed, monitored and treated. This solution has high disruptive potential and can be implemented across Europe and beyond to reach a large worldwide market. Prototypes of various SMA miniature valves are already available. In the past year several pilot customers acquired paid developments and application-specific projects were transferred to series production (30,000 – 50,000 pieces). Currently, incoming 2018 orders are of low 6-digits providing a solid basis to achieve this years turnover objective. Our traction has already been substantial. Besides the EXIST Research Transfer Phase I grant, we have attracted equity investments and we have received the following awards: 1st place KIT Venture Fest Gründerpitch (Aug 2016), 1st place Elevator Pitch Baden-Württemberg (Jun 2017), Winner WECONOMY (Jun 2017), Init Innovation Prize Cyber Champions Award (Aug 2017), 2nd place CyberOne Hightech Award (Oct 2017) & 4th place at VC Pitch BW (Feb 2018). Further, we have qualified for the 2nd round of the CoHMed Connected Health application process.

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Company Name MEMETIS GMBH
Address Gablonzer Strasse 27 76185 Karlsruhe
Web Site https://cordis.europa.eu/project/rcn/220171/factsheet/en

10.

ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE

Customized photonic devices for defectless laser based manufacturing

  • 5 Million
  • Spain
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Customized photonic devices for defectless laser based manufacturing
Company Name ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE
Funded By 38
Country Spain , Western Europe
Project Value 5 Million
Project Detail

Different beam shaping technologies, appeared in recent years enable to tailor energy delivery using a tailored spatial and temporal power distribution in laser beam. This makes possible to solve relevant metallurgical problems, such as hot cracking in Laser Beam Welding (LBW) and Selective Laser Melting (SLM). However, the desired thermal history (temperature range and cooling rates) is specific for each material. In other words, it is material- and process-specific so the exact beam shape must be customized to the specific alloy and process in question. This is not exclusive to LBW and SLM, but also to other laser-based manufacturing scenarios where a certain thermal history is needed for precise microstructure tailoring. CUSTODIAN aims to develop a methodology of application-driven laser beam tailoring of the material microstructure and deploy this beam to solve hotcracking in LBW and SLM. CUSTODIAN will rely on beams with specific shape and spatial energy distribution, designed upon the metallurgical studies and multiphysics simulation for each combination of process and material. To accomplish the deployment of customized beam shapes in relevant industrial environment, the consortium will perform a twofold photonic development: (1) a compact, robust and dynamic beam shaping technology (Multi Plane Light Conversion, MPLC) and (2) a closed loop inline control system based on uncooled SWIR/MWIR sensors and an FPGA architecture to ensure the quality and dynamicity of the beam shape requirements. The application scenarios of CUSTODIAN are: LBW of austenitic steel for exhaust systems in automotive and SLM of nickel superalloys in energy and aeronautical sectors. The developed methodology for application-driven beam shape design will be protocolized to facilitate its future extension to other laser-based processes with (e.g. laser metal deposition) or without material addition (laser tempering, laser softening, etc.) as well as to other shaping technologies.

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Company Name ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE
Address ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE Address Calle Relva Torneiros 27a 36410 Porrino Spain
Web Site https://cordis.europa.eu/project/rcn/219087/factsheet/en

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