ADDIFLAP: Aditive Manufacturing of Flap Tracks based on Laser W-DED Process

ADDIFLAP will develop a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new maintenance-free design of carriage system based in a sliding pad concept. The development of the W-DED-LB process will be supported by numerical models including an online process monitoring & control, in order to stablish manufacturing strategies that minimize distortion and achieve the required structural integrity. The sliding pad design for the flap carriage system will rely on self-lubricant surfaces for controlling friction and reducing wear.

ADDIFLAP will reach TRL6 Level, demonstrating the performance of W-DED-LB in a real manufacturing environment and getting the final validation of the flap track structure under dynamic conditions. Additionally, the validation of the self-lubricant surfaces that enable the redesign of the carriage system through a novel sliding concept will be carried out. The wear occurring between the sliding pad in contact with the additive manufactured track will be assessed using component tests in order to ensure the performance of the self-lubricating sliding pads.

The new manufacturing strategy of ADDIFLAP will impact the whole value-chain, improving the environmental impact and the industrial competitiveness: raw material saving, energy-efficiency and overall optimization. W-DED’s CO2 emissions are only 26% compared to CNC machining. On the other hand, a material saving of around 60% of titanium waste per component is expected compared to machining.

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 This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under grant agreement No 101007901. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.