Reliable process parameter sets for LMD

This deliverable describes the technical challenge in the selection of the aluminium alloy, the DED-LB/P system and characteristics as well as the development of suitable process parameters and manufacturing strategies for reinforcement structures on thin metal sheets. Various factors influence the choices taken such as the availability of aluminium alloy powder in the market, thickness of the substrate material on top of which the reinforcement structures are deposited and maximum allowable thermal deformations. The deliverable also highlights the common challenges of processing aluminium alloys with lasers, with a focus on both material quality assurance as well as obtainable geometrical accuracy of the manufactured parts. Several sensors-based solutions and feedforward- and feedback-controlling strategies are proposed in this deliverable to attenuate in the future the identified challenges and to increase the TRL of the technology to reach a system that can be used for series production in an industrial environment.