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AEROSPACE AND AUTOMOTIVE| 12 |Laser additive manufacturing:Building SA’s future one layer at a timeThe CSIR is developing a suite of unique laser additive manufacturing systems and processes that will place South Africaat the forefront of this technology, with tremendous potential benefits for the local manufacturing industry.Compared to conventionalmanufacturing technologies whichare often subtractive (materials areremoved via cutting or milling),additive manufacturing relieson various energy depositiontechnologies to fuse materialsinto three-dimensional functionalparts; materials are joined to makeobjects, one layer at a time. Laseradditive manufacturing (LAM)allows for this to be done usinglasers.This emerging manufacturingtechnology lends itselfto the development ofcomponents from uniqueceramic, alloy and light metalmaterials. It will be key inthe beneficiation of SouthAfrica’s titanium resources– around which efforts arebeing accelerated to establisha titanium industry – andaffords the local aerospaceindustry a significantcompetitive advantage overinternational competitors.This innovative technologywill be used for the productionof unique finished goodsfor the aerospace, defence,automotive (in areas such asmotor racing) and medicalindustries. It is against thisbackdrop that the CSIR hascreated a programmefocusing specifically onadditive manufacturing.The goal of the additivemanufacturing programmeis to promote andadvance the knowledge,capabilities, and economicopportunities in this fieldfor the benefit of localindustries. To achievethis objective, the CSIRwill focus its resources onsupporting three maininitiatives in additivemanufacturing.Deputy Minister of Science and Technology, Derek Hanekom, third right, recently officiated at the launch of a new additive manufacturing facility at the CSIR. Also present were, fromleft, Dr Paul Potgieter, group managing director: Aerosud; Dr Federico Sciammarella, manager of laser materials processing, CSIR; Dr Ndumiso Cingo, manager of the CSIR National LaserCentre; Dr Sibusiso Sibisi, chief executive officer, CSIR; and Dr Hoffie Maree, group executive: operations, CSIR.Laser metal depositionadditive manufacturing(current state-of-the-arttechnology)During 2012, the CSIRwill establish an additivemanufacturing workgroup,focusing on laser-engineerednet-shaping (LENS) technology,with academia, industry andrelevant government agencies.“LENS technology uses a highpowerlaser (500 W to 4 kW)to fuse powdered metals intofully dense, three-dimensionalstructures,” says Dr FedericoSciammarella, manager of lasermaterials processes at the CSIR.“The LENS three-dimensionalsystem uses the geometricinformation contained in acomputer-aided design solidmodel to automatically drive theLENS process as it builds up acomponent, layer by layer,” henotes.Additional software and closedloopprocess controls ensurethe geometric and mechanicalintegrity of the completed part.The goal is to identify criticalcomponents and industries,in addition to the identifiedtarget markets in aerospaceand biomedics, that can benefitfrom either manufacturing orrefurbishment/repair usingLENS technology. The CSIRwill be a key link and driverin coordinating and forgingpartnerships of potential users.High-speed, large-areaselective laser melting(cutting-edge technologydevelopment)In a second project, called‘Aeroswift’, the CSIR hasteamed up with Aerosud, anestablished leader in the SouthAfrican aviation industry.The main goal of this projectis to establish a functionalfirst-generation, high-speed,large-area selective lasermelting system that will becapable of building aerospacecomponents with dimensionswithin a range of 2 m by0.5 m. Such a system iscurrently not availablecommercially and thereforewill have a niche marketwith high impact, as thereare a variety of aerospacecomponents that fall withinthese dimensions. Creatingthis technology in South Africain collaboration with theTitanium Industry Initiativewill contribute to South Africaincreasingly becoming a keyplayer in the aerospace sector.Major aerospace companieshave indicated that they arepaying close attention tothe success of this project,with 2016 targeted for a fullyoperational system, capableof producing its first parts.This would be a tremendousboost to the manufacturingsector in South Africa andwould allow companies likeAerosud to expand theirproduct range. It would alsosee South Africa cover thefull value chain from a rawproduct (titanium powder)to high-value components.Ultra-high-speed laseradditive manufacturing(next-generation, radicaldesign technologydevelopment)For the third project, called‘Umuvi’, the long-termobjective is to create futuregeneration high-speed,large-area, laser additivemanufacturing systems,to stay ahead of the trendworldwide and capture futurerevenue streams by meetingResearchers and engineers from the CSIR National Laser Centre and Aerosud have teamedup for project Aeroswift. They are working to create a functional first-generation, highspeed,large-area selective laser melting system that will be capable of building aerospacecomponents with dimensions within a range of 2 m by 0.5 m.future demands for moreefficient and higher productivitysystems.“The underpinning technologyfor all these projects is laserenabledadditive manufacturingand our LENS system will setthe tone for the Aeroswift andUmuvi projects. The systemenables immediate entry intothe refurbishment market,where worn-out parts orcomponents are repaired, andthe working life or performanceof the component becomeseven better, compared tothe original part,” saysSciammarella. “If we succeedin showing the value of thistechnology, projects Aeroswiftand Umuvi will be welcomedby industry,” he adds.“Successful completion of theseinitiatives will see the creationof a knowledge base andcapacity that will enable SouthAfrica to generate sustainablewealth and future opportunitiesin additive manufacturing,”concludes Sciammarella.Also read the article onpage 84.Enquiries:Dr Federico Sciammarellafsciammarella@csir.co.zaumuviUmuvi is an IsiZulu wordfor wasp: A winged insectthat has a narrow waistand a sting. It constructsa nest from wood pulp ormud, pictured above (usingthe principles of additivemanufacturing, left).| 13|