In order to overcome current technical and technological
deficits in production-driven repair welding and recovery
services, the overall goal of the project is to develop and
introduce advanced processes and production technologies on
3D metal surface processing and net-shaping into the field
of repair welding and recovery services. Special
consideration will be given to technologies capable of
improving the reliability of processed applied to deposit
or remove material and integrated production automation
The work programme is specially tailored to meet the
specific demands of industrial users on the basis of a
common platform for transnational exchange of experience
and know-how as well as cooperative R & D.
Five major research areas will be addressed:
1. Advanced technologies with near-to-net-shaping in
cladding material removal processes
2. 3D sensing, modelling, simulation and data processing
3. Simulation-based process planning and adaptive control
4. Integrated production automation and robotics;
5. Quality assurance.
Specially addressed are high performance processes for
material deposition and removal like welding, taping, laser
processing, polishing or grinding as well as hybrid
solutions. In parallel, the project intends to develop and
implement integrated production automation concepts for
repair welding and recovery services.
In this context studies and investigations on cross-
sectional disciplines are of essential importance.
Addressed are 3M measuring and sensing techniques,
digitization strategies, modelling as well as material
properties, near-to-net-shaping strategies, process
simulation and real-time control, quality assurance,
production process engineering, data management, automation
and industrial pilot studies.
Within the framework of PROSURF, various industrial
partners and research providers from five European
countries will collaborate, based on enhanced synergies to
overcome current deficits and problems in 3D metal surface
net shaping applied to repair welding and recovery
services. The expected results are of multi-sectorial and
multidisciplinary character. Based on a modular system
design, the project results are of border crossing interest
and applicable in many different areas of industrial
production. Industrial benefits can be expected for
instance in rapid tooling, moulding, tool and machinery
component repair and recovery services, manufacturing of
complex metal structures and parts, forming and forging,
casting, prototyping, reverse engineering and many more.
Looking at the problems faced by the industry today, the
research work will be subdivided in 4 sub projects:
I. Repair and regeneration
- regeneration of press and forming dies
- turbine blade repair.
II. New technologies for mould design and tooling
- cladding with MIG/MAG, TIG and PPA technology and
integrated, near-to-net shaping capabilities
- structuring of 3D surfaces with diode laser technology
- selective removal of material with diode laser technology
- recovery with taping technology
- surface coating.
III. Finishing and Surface Structuring
- finishing of parts for mass production by magnetic
field based grinding and polishing.
IV. Process Automation
- 3D topographic sensing
- repair welding with robots
- simulation-based process planning and adaptive control
- automation in closed process chains.
The project results will be tested exemplary on pilot
applications such as turbine blade repair, barrel extruders
and forming dies, thin coating of high pressure vessels and
recovery of machinery components. Most of the pilot
applications are directed at SME partners who expect to
increase economic efficiency and competitiveness by the
introduction of advanced technologies into a more or less
manually-driven production environment.
Dissemination planned within the project work will include
technical workshops and demonstrations, seminars, published
reports and conference presentations. It is intended to
establish a PROSURF user group which will advise and
observe the project work. Moreover, a network-based
communication platform for information exchange and
dissemination of results will be established by use of the
Internet. It will be open to all who are interested in this
special field of advanced production technology.