Inline process chain development for repair methods for recycling AMC materials (short: AlMeCoRe³)

CMMC GmbH; METROM Mechatronische Maschinen GmbH; access e.V.; BTU Cottbus Fachgebiet Hybride Fertigungstechnik und Fachgebiet Elektronische Schaltungstechnik

March 1, 2024, to October 31, 2025
(funded by BMBF - WIR! – Change through Innovation in the region)

In-situ process monitoring using IR thermography to identify defects in weld metal makes it possible to quickly locate defects in three dimensions within the weld metal. In contrast to conventional methods, which require the component to be transported to the measuring system, IR thermography can save a lot of time. Integration into the process chain for defect minimization also offers the unique opportunity to eliminate defects in a targeted manner. This avoids scrap or complicated repairs afterwards. By focusing on an innovative lightweight material, namely AMC (aluminum alloy plus ceramic particles), the IR thermography system must be trained using AI so that the particles (different appearance and property profile) are not detected as defects. The simulation of the processes and the entire process chain is particularly relevant for use in the mobile repair factory and requires a high degree of material properties and experience in order to be able to use the simulation effectively for AMCs. Only in this way will it be possible to position the machining heads for the elimination of welding defects in the process chain for “quasi in-situ” repair. Simulation allows many parameters and their interactions to be visualized and optimized even before actual use, thus facilitating mobile deployment.

The project lays the foundation for mobile, AI-supported repair of welding defects in AMC materials. Integrated in-situ monitoring and simulation-supported process chains reduce waste, increase component quality, and strengthen the industrial usability and circular economy of innovative lightweight materials.