Fraunhofer Institute for Production Systems and Design Technology
Fraunhofer Institute for Production Systems and Design Technology

FERA II – Ferramentas Manufaturadas Aditivamente II

FERA II is developing an adaptive digital process chain for the rapid detection of damage and subsequent additive repair of tools used in the automotive industry. By combining 2D anomaly detection, 3D difference volume determination (»as-is« vs. »as-designed«) and additive repair processes (DED-LB/M and cold spray), the project reduces downtime and repair costs and increases tool life.

FERA II expands on the work of the first FERA phase and further develops the digital repair chain so that it also works reliably in practice for large, complex tools.

Key elements

Integrated 2D/3D damage analysis and repair: AI-based 2D and 3D defect detection, DED-LB/M simulation, and cold spray optimization in the demonstrator

  • Combination of fast 2D anomaly detection and precise 3D measurement to determine surface damage and volume differences for repair.
  • Automated 2D-3D mapping: Anomaly heat maps from photos are localized on the CAD model. These are used to generate integrated damage models, which are further processed as STEP files.
  • Development and calibration of a numerical simulation model for DED-LB/M (thermal structural welding simulation) to optimize process parameters and prevent cracking and distortion. Validation through experimental welding tests.
  • Investigation of cold spray specifically for cast iron tools as an alternative repair and coating method, as cold spray does not require melting and therefore presents a lower risk of cracking. Selection and optimization of two alloy systems and parameters as well as test components for demonstration purposes.
  • Integration of all modules into a demonstrator, knowledge transfer and customer-oriented implementation, as well as exploitation activities (immersion in Germany, transfer workshop in Brazil).

Services provided by Fraunhofer IPK

Fraunhofer IPK is responsible for the design and application-oriented development of the technologies used in the project. The broad spectrum includes both the use of hardware and production machines as well as the implementation of a digital process chain. An integrated inspection system with 3D scanners and cameras is being developed and operated for 2D and 3D defect detection. The systems for DED-LB/M and cold spray enable investigations of the manufacturing processes and parameters. For the automated process chain for processing the data, 2D anomaly detection and 3D difference volume determination are combined in a modular manner and path planning and manufacturing simulation are integrated with the aim of achieving a generative, versatile solution. Transfer workshops and immersions in Berlin and at the Brazilian project partners' sites ensure the transfer of knowledge and technologies.

Collaborative partner

  • Client: Fundação Casimiro Montenegro Filho (FCMF)
  • Instituto Tecnológico de Aeronáutica (ITA) with the Fraunhofer IPK Project Office for Advanced Manufacturing located there
  • As a technology partner, Impact Innovations GmbH contributes its expertise in the field of cold spray processes.

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