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Two different types of case studies can be done in cooperation with RAMLAB: A repair case study and a WAAM case study.
Repair case study
In a Repair case study RAMLAB’s technology is used for the repair of a metal part of choice. RAMLAB offers an integrated method for repairing and regeneration of forging dies and molds consisting out of the 3D scanning of the damaged part, robotic welding system and additive toolpath generation software and tailor-made consumables.
- Increased productivity
Automate repair activities that significantly increase the lifespan of your equipment.
- Reduced human interaction
Less exposure of workers to unhealthy conditions
- Reduced material costs
Less material needed due to near net shape repair and regeneration
WAAM case study
In a WAAM case study RAMLAB’s technology is used to print a metal part of choice up to 6 meters. The benefits of this include:
- Reduced lead times
For rapid production of custom parts, one-offs and functional prototypes
- Reduced material costs
Near net shape production of parts made out of exotic materials such as inconel.
- Production of quality parts
Exceptional quality parts compared to sand casting due to real time monitoring of the production process.
Steps in a case study
1. Part selection
The first step in every WAAM process is the selection of the to-be manufactured part. This selection is based on the required specifications and the expected business case. At the start of the process also the choice is made whether certification of the selected part is required.
2. (Re-)Design for CAD/CAM
Based on design rules for WAAM a CAD model for a pre-form is made. This pre-form is a near net shape of the actual part that can be milled to final dimensions. The CAD model uploaded to the MaxQ Webapp.
3. Material selection
Based on the intended mechanical properties a selection for a material and wire feedstock is made. A number wire feedstocks have been evaluated in earlier projects. For the material selection we work closely together with welding thread producers Voestalpine and Lincoln Electric.
Based on the digital model, choice of material and several tests, the MaxQ Webapp creates a toolpath for the welding robot to follow. This toolpath is uploaded to the robot and production is started at the RAMLAB premises.
During production RAMLAB’s MaxQ system is used to monitor and control the production. In this way the production quality data can be assessed and stored.
6. Post processing
Depending on the requirements, the part will be milled, heat treated and/or post processed in other ways.
7. Quality testing
Both non-destructive and destructive tests can be executed, depending on the requirements defined in step one.
Throughout the whole WAAM process all choices, tests and other information are documented in detail. This information is gathered and presented in written form.
During the evaluation the business case is (in)validated, and the decision for proceeding in buying a WAAM cell with MaxQ is made.