Institut Marey -Maison de la Métallurgie, 64 B Rue de sully 21000 Dijon
This paper concerns a French plan of actions for a concerted deployment in Bourgogne and in Lorraine of HIP (CIC: Compaction Isostatique à Chaud in french) equipments named CICéRON. This latter will be in direct connexion with the powder metallurgy emergence. It will develop metallurgical industries of the future with high-value-creating jobs of tomorrow on French strategic segments such as aerospace, automotive, railways, energy and defense.
To promote powder metallurgy, diffusion joining, rapid prototyping (direct net-shape manufacturing) and post-treatment by densification of metallic parts from additive manufacturing, the concerted construction on the national territory of platforms equipped with HIP equipments whose complementarity will cover the whole chain of maturation appears fundamental to the leaders of the project CICéRON. Face to the importance of the investment in HIP equipments to raise the technological and industrials locks, especially those which relate to the mastery of the scaling-up, the project leaders of Burgundy and Lorraine regions, have decided to join us in order to bring a best response to the requirements of powder metallurgy network.
This complementarity allows us to satisfy all economic, technical, environmental and organizational challenges through a national project for the development of the CICéRON and to present a gradation of multiple HIP machines on the national territory, with a goal of deployment of operational platforms of 2018. The project will be composed of three phases in direct relationship with the dimension of samples produced by these HIP equipments.
The first is CICéRON 200 with an HIP of small sizes for levels of TRL ranging from 1 to 3, in particular, a HIP machine of 200 mm in diameter installed at the University of Bourgogne in Dijon (December 2015), which will complement the CIC-100 mm already installed for several years at the CEA Liten to Grenoble.
CICéRON 660 - A second level of diameter 660 mm located at Le Creusot in order to make developments (TRL 3 to 7) preparing the industrialization of parts by the CIC technology, then the production of small series, in the framework of a Center in Powder Metallurgy for the research and development and the semi-industrialization. This latter will be in direct connection with CICéRON 200. The enclosure will be versatile and well instrumented.
CICéRON 1600 - A third level of diameter 1600 mm has for objective to equip the Lorraine of a platform of industrial size essential to meet the challenges of industrial tomorrow for the three main applications that are powder metallurgy, welding by diffusion and 3D printing for the metal (TRL 5 to 9). The enclosure can also be used to repair the foundry parts of large size.
The University of Bourgogne, associated to the French cluster of Nuclear Industry (PNB), wish to establish a center of excellence in powder metallurgy in Burgundy for the semi-industrialization of large metallic or ceramic components and / or complex shape to meet the industrial needs. Burgundy has already a network of industrial, laboratories and platforms of the University of Bourgogne, allowing relying on real skills in relevant areas (metallurgy, mechanical and non-destructive testing).This center will have the ambition to offer the manufacture of metallic and ceramic prototypes of parts/assemblies with complex shape and / or large dimensions in a semi-industrial version by means of powder metallurgy. This center will be multi-sectoral and will serve all industries as Aerospace, Nuclear, Oil & Gas and Defense.
This center of excellence CICéRON 200, located in the new building named Institut Marey - Maison de la Metallurgy will have three operational machines already purchased: two SPS machines (Spark Plasma Sintering) and one HIP equipment (Hot Isostatic Pressing) which will be installed in December. The official opening of this center will occur after the French HIP 2016 conference organized by SF2M at Dijon (February, 2nd 2016).
Location of CICERON 200 at Dijon, it corresponds to the number (2) in the left figure.
Equipments present in CICéRON 200 (Dijon): (a) SPS equipment for research (10 to 40mm) (b) SPS equipment for for both R&D and industrial manufacturing (30 to 160 mm) (c) HIP for both R&D and industrial manufacturing (30 to 200 mm).
This center of expertise CICéRON 200 will consist of 8 highly qualified people (engineers, PhD) to meet the needs of manufacturers and laboratories wishing to conduct operations on powder metallurgy for components and assemblies with dimensions up to 200 mm.
The main aims and ambitions are to:
- Manufacture by powder metallurgy prototype parts and assemblies of metals and ceramics and with complex shape at an industrial scale.
- Control these parts using innovative technologies of non-destructive testing (surface and dimensional).
- Accompany the industrial partners in all stages of the product manufacturing from design to realization at the industrial scale including recycling step.
- Provide training sessions for the industrial partners in powder metallurgy and in innovative non-destructive technologies.
- Qualify the product (determination of lifetime, mechanical properties and corrosion resistance as well as controls associated to manufactured parts and assemblies: non-destructive testing and geometric controls) according to the codes and standards.
The ambition of CICéRON 200 is to determine the feasibility in production, cost and skills for metal parts by powder metallurgy means. The Industrial partners will have decision criteria to produce such parts or assemblies to a larger manufacturing scale in powder metallurgy for their company. CICéRON 200 will realize all stages from fundamental research (choice of powders, selection of good mechanical properties, choice of processes, simulations, basic prototyping and feasibility) to prototyping and control of the components to demonstrate the technical and economic feasibility of the final product. For small components, CICéRON 200 can provide products of small series. These steps take into account the durability and the recycling of products. It is essential to demonstrate, beyond the possibility of manufacturing the part or assembly, if this last one has a lifetime similar or greater compared to the product performed by a traditional production way and if potential gains in energy and raw materials are achievable. Similarly, the recyclability of materials is essential for sustainable development of the industrial chain.
It will be important to demonstrate to industrial partners if the new process of powder metallurgy manufacturing will provide greater performance for his product in terms of:
- mechanical properties, homogeneity and control of materials, lifetime (essential in aeronautics, aerospace and nuclear industries for strategic components such as nuclear power plants components (60 years) and aircraft (engines and landing gears)),
- recyclability of materials, manufacturing cost, product cycle time compared to classical manufacturing (forging, casting, machining, welding, rolling, heat treatment, extrusion,…),
All these criteria will help on the choice for designing the product in the future. In addition, the gain of raw materials and the minimal use of finishing processes (machining, heat treatment) will be important criteria for the manufacturer to measure the costs involved in the production of the part or assembly using powder metallurgy.
Pr. Frédéric BERNARD, Université de Bourgogne (ICB – UMR 6303 CNRS)
Tel : 06-87-46-90-84
Dr. Nicolas RICHARD, Pôle Nucléaire de Bourgogne (PNB)
Tel : 06-18-55-68-98