rates. FDM (Fused Deposition Modeling) technology is being developed, applying high-power ultrasonics, while also experimenting with the use of microwaves. Developments in Ultrasonic-based FDM have already led to the creation of a prototype unit at Ascamm, and work is Injection moulding is a complex process where ensuring the currently being done on optimising the design of the sono- quality of the manufactured part depends on a number of pe- tion me- trode and improving process control variables. A prototype critical, mutually linked parameters, especially the tem unit to validate tests on microwave sintering of metals rature and pressure within the mould during the injec performed in collaboration with an Israeli partner is also process. Just one anomaly in any of these process para being proposed. The aim with this technology prototype is to ters can affect the final quality of the parts. The need there- define the feasibility of different process configurations: fore is to make modifications in the mould and configure the cladding or powder bed set-ups. Both organisations have machinery parameters to ensure to optimise quality of the patented the development. part before going onto the production phase. The aeronautics sector has always formed part of the rience of expert technicians, along with numerical simula- vanguard in the use of high performance metal materials tions that require a lot of computing time to simulate the and the development of innovative metal processing tech- surface of the mould’s geometry. nologies to make complex parts with high mechanical The Ascamm technology centre has developed an innovative, demands. knowledge-based solution that can identify the type of Ascamm is highly active in this sector and currently colla- sensor and the best location in the mould using a set of borates in the design and manufacture of a number of parts parameters. The solution is a hybrid system that brings that will be assembled at the test bench of the CROR (Contra together case-based and rule-based reasoning, or rather, it Rotating Open Rotor) for Snecma. The CROR is a high-effi- uses the tacit knowledge of experts to create a powerful tool ciency rotor concept that will make fuel savings of up to 35%. that adds intelligence to the process. This solution is the first Major European aeronautics manufacturers of engines, step towards a totally automatic mould sensorisation modules and engine sub-systems are also involved. process. / Ascamm is developing several sub-sets of parts for contra- rotating rotors, of up to 1.5 metres diameter, made of tita- nium and nickel alloys, and thermosetting compound materials with carbon fibre. Aeronautics, at the forefront of new metal components These days, it is common practice to insert sensors inside the mould to monitor and predict the quality of the final parts before opening it, which allows the process to be auto- mated. However, one of the great unknowns in this process is: what is the minimum size of the set of sensors and where is the best location inside the mould to obtain the right infor- mation to optimise the process? Work is being done to answer these questions, using the knowledge and expe- Overcoming the challenge of smart moulds Report / 29