1 September 2018
Additive Manufacturing (AM) allows decreasing production time and overall cost for building variable and lightweight vehicle structures. Using AM, almost any complex geometry can be processed. This opens up a vast freedom for the design of lightweight structures and components. In order to develop the technology for producing these structures and overcome challenges forseen in materials, process parameters, design methodologies and testing approaches, the University of British Columbia (UBC) in Canada and the DLR in Germany have joined forces into an international collaborative research project.
The UBC Department of Materials Engineering and the DLR Institute of Vehicle Concepts will examine hybrid structure manufacturing approaches through the combination of additive and conventional manufacturing of metal components. An AM process employing Electron Beam Welding (EBW) provides the technological scope to build hybrid structures through combining cast components with additively manufactured joints and local reinforcements e.g. ribs and patches.
DLR Institute of Vehicle Concepts
The institute addresses the development of future technology systems for sustainable, safe, and affordable generations of vehicles on road and rail. The institute's contributions range from conception and design through construction, calculation, and simulation to the presentation of research demonstrators, components, and vehicles.
UBC Department of Materials Engineering
The Department of Materials Engineering is internationally recognized for their expertise in materials and manufacturing. They bring a broad expertise in materials synthesis, characterization and simulation to the field of additive manufacturing. Further, UBC’s facilities comprise several state-of-the-art research benches to conduct and verify among others large-scale experiments, manufacturing processes, and material characterization.
The focus of this work is to develop a process specific material testing and modeling approach for welded joints and structural elements created by EBW on cast aluminum members. Variations of member geometries, material and process parameters have to be produced, identified and evaluated in order to determine suitable parameter sets for automotive load bearing structures.
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