- Instead of waiting months for a new part or tool, Guaranteed reduces the downtime of expensive installations by repairing the parts or tools in a much shorter time.
- The maximum dimensions in the current WAAM cell are 10 by 5 by 6 meters, with manipulators capable of handling up to 10 tons
- The hybrid approach is an example of this cost-effective solution. If you only 3D print the specific features on, for example, a CNC milled or turned part, you can save a lot of time and costs and still take advantage of the design freedom of additive manufacturing
AM company Guaranteed has left the startup phase behind and is preparing for further growth. Among other things, this growth should come from the production of hybrid components: features applied with additive manufacturing to a conventionally manufactured base. “With the demonstrators that we are developing together with partners in the 3DOP (3D Printing Optimized Production) project, we want to demonstrate that this hybrid approach has added value”, says Joachim Antonissen, founder and CEO.
In one of ArcelorMittal’s former factory halls in Zelzate, Belgium, Guaranteed has been using WAAM (Wire Arc Additive Manufacturing) to restore valuable machine parts and tooling from the steel industry, among others, for several years. What began as a research project of the steel producer together with OCAS, the Belgian steel industry research institute, has established itself as a lasting value in the Belgian AM industry. The motivation to choose Guaranteed’s WAAM approach is mainly the shorter lead time the company can guarantee. Instead of waiting months for a new part or tool, Guaranteed reduces the downtime of expensive installations by repairing the parts or tools in a much shorter time. Another benefit is that customers can reduce their inventory of spare parts as a result. The focus on repair work is additionally driven by the sustainability narrative.
Shorter lead time
The young Belgian company is especially looking for recurring work, parts that have to be refurbished once in a while. For example, Guaranteed has won a contract with ArcelorMittal Gent to restore large support rolls from the continuous casting line. “Our technology has been validated as a default technology. The forecast is that we will process about 100 rolls per year. On each roll 8 to 16 domes have to be welded on”, as Joachim Antonissen explains this contract. Repeat orders create the possibility of automating the process, for example by using fixed fixtures to clamp more efficiently. With repeat work, it is also easier to make arrangements with external parties who do post-processing. Larger runs are reworked by external partners; smaller ones in-house. “And we can then amortize development costs over multiple roles”, Joachim Antonissen adds another advantage of recurring work. Now that Guaranteed has become the preferred supplier for the Gent site, it is trying to fulfill the same role for ArcelorMittal’s other European sites. And for other potential heavy industry clients.
Together with Valland, one of the project partners, we have shown that with this hybrid approach we can save 35% material and see 35% performance improvement by modifying the design of the valve
Process control: more possible than allowed
From both the materials database and the production database, Guaranteed demonstrates the possibility of using Machine Learning to properly predict the mechanical properties of the WAAM components. Similarly, based on the desired weld geometry, one can predict which welding parameters should be used. This opens the door to a control loop system for the WAAM plants in Zelzate. Unfortunately, this is not yet accepted by the certification companies. Joachim Antonissen: “They prescribe fixed recipes. Logical, after all, the standard comes from the industry’s desire to have a stable solution and from the insurance rationale behind certification. They are not yet ready for this step.”
Growth ambitions with hybrid components
There are currently two robots and three manipulators in Zelzate. By the end of 2024, the capacity should be doubled. “After that, the next step should then follow geographically outside Belgium”, says Antonissen. “The core competence remains in Belgium. Abroad, satellites would then be established in order to do the work close to the sites of future customers.” The planned expansion in Zelzate includes increasing the dimensions of parts that can be welded on. The maximum dimensions in the current WAAM cell are 10 by 5 by 6 meters, with manipulators capable of handling up to 10 tons. One of the applications Guaranteed expects a lot from is the near net shape 3D printing of large tools and dies, for example for the automotive industry. A hybrid application for the Norwegian shipping industry also offers prospects. Guranteed 3D prints pins on a rolled plate as an alternative to forged crankpins. “Our shorter lead time allows us to solve the delivery problems for this part at our customer’s site”, explains Joachim Antonissen. The application has been validated by DNV and Guaranteed has now printed the first series of crankpins.
The hybrid approach
This hybrid approach should overcome the economic barriers that 3D printing faces. WAAM can be a good alternative for heavy castings, say of 500 kilograms and more. “But if the customer is satisfied with the quality level of castings, it‘s almost impossible to valorize the additional cost and improved mechanical performance of WAAM”, Antonissen clarifies the dilemma. For New Parts Production, Guaranteed is therefore looking for the hybrid solution: the specific features for which additive manufacturing offers added value are applied to a basic component made with conventional technology. This has functional, economic and ecological advantages. These are the reasons for Guaranteed to participate in the 3DOP project, in which it operates in the work package on metal printing. Within this work package, the boundaries for 3D metal printing are being pushed, both by repairing expensive components and by finding solutions to make 3D metal printing more cost-effective. The hybrid approach is an example of this cost-effective solution. If you only 3D print the specific features on, for example, a CNC milled or turned part, you can save a lot of time and costs and still take advantage of the design freedom of additive manufacturing. Joachim Antonissen: “Together with Valland, one of the project partners, we have shown that with this hybrid approach we can save 35% material and see 35% performance improvement by modifying the design of the valve. The design modifications made with respect to a casted geometry were added to print less material and ease the manufacturing process.” The 700 to 800 mm diameter valve weighs 80 to 90 kilograms and can be produced cost-effectively with AM. Machining only the surfaces that attach the valve to the rest of the plant further reduces costs. Guaranteed is also looking at applications in the oil and gas industry, exploring with the university in Leuven (KU Leuven) how to print multiple alloys in one component. “With WAAM, this task can be done easily. As long as the materials are metallurgically compatible, we can switch without additional production complications.”
Need for demonstrators
At the end of the day, these demonstrators must prove the viability of hybrid additive manufacturing. For Joachim Antonissen, participating in the 3DOP project and sharing knowledge. are steps in this direction that he could not easily take outside the European project. “For many customers, AM is still a leap in the dark. It is of course not only a matter of having the resources and funding for a proof of concept. This project gives us the opportunity to reduce the customer’s risk and, in the meantime, demonstrate the added value of WAAM. This should ultimately remove one of the barriers to additive manufacturing.” Joachim Antonissen is confident. “The hybrid crankpin is the result of a project that ran a few years ago. Now we are a series supplier to the Norwegian company. If one of the cases from the 3DOP project is industrialized, I will be happy. Because the network we are building is invaluable for future work.”
Unique to the 3DOP project Joachim Antonissen has been involved in European Horizon projects in the past. What he finds unique about the approach of the 3DOP project is that in addition to the technology angle, there is also a focus on knowledge dissemination. “We now really have a partner in the project for whom this is the main activity. This allows us to increase the impact of what the other partners are investigating.”
