Usage and Service Life Analysis
The scalable production technology developed at SCALE may introduce scale-related component defects and variations in manufacturing accuracy. Deployment of autonomous, parallel-working robotic units can generate geometry and material inhomogeneities – such as notches, offsets, or distortions – potentially compromising structural stability.
These defects must be identified, and their impact on subsequent service life and reliability predicted.
Research Focus Area 6 therefore develops holistic validation of the investigated manufacturing technologies alongside scale-independent methods for usage and service life analysis. This utilises component-integrated sensor systems and 3D measurement techniques from Research Focus Area 5. Sensors are adapted to varying component sizes, calibrated, and networked via suitable topologies with integrated wiring and contacting methods, enabling data processing directly at the sensor node. Prospective developments include intelligent, autonomous sensor nodes capable of wireless data transmission and self-powering through energy harvesting.
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Alphatradezone auf Pexels
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Kevin Shek auf Unsplash
Complementarily, precise 3D metrology creates a digital twin of the component for condition assessment of function-critical geometry elements and comparison against nominal geometry. Optical measurement methods from Research Focus Area 5 provide the foundation for multiscale geometry capture.
This enables novel approaches to detecting and characterising wear and damage mechanisms in large components under real operating conditions.
