Projects

PALES - L488/92 (C)

Design techniques and simulation for structural elements for light railway, naval and civilian applications.

Aim of the Project: design and construction of innovative laser-welded structures for naval applications (light alloy platforms for vehicle loading) and railway applications (structural panels for railway carriages).

SINAVE - L48/92 (T)

Innovative system for intermodal transport by fast ship.

Aim of the Project : (CALEF task) design and construction of innovative structures (containers) made with light alloys and welded with lasers for the transport of goods on fast ships

LACER - L297/99 (C)

LAser CERamico a stato solido di alta potenza/ Laser high power solid state ceramic

Aim of the Project objective: realization of an innovative high power laser system based on the use of transparent ceramics to replace the crystalline active medium to be used for cutting and welding light alloy panels for naval use.

ALISCAFO AD ALA IMMERSA (T)

HYDROFOIL WITH SUBMERGED WING L. 297/99

Project objective: (CALEF task) development of the laser welding process of the submerged wing component, mechanical tests and functionality study

SMART FLEX -GPS

Aim o the Project : development of innovative solutions in the area of production systems which, through the creation of autonomous elementary cells,specialized by type of process and by product families, allow a rapid reconfiguration with changing conditions of use

ENVIRO-ALISWATH (T)

Hybrid ship carrier FOILS / SWATH - PON 2002/06

Aimi of The Project: (CALEF task) study and model simulation of structural components

MAVET (T) - PON 2002/06

Advanced modules for collective transport carriers.

Aim of the Project: research and development of modules for collective passenger transport vectors that allow new flexible architectures for different applications (railway, tramway, metro carriages, etc.) and / or for different functions within the same vector. The Project was divided into the following areas of development: innovative materials and related production processes and techniques, advanced simulation techniques, calculation and virtual design, design methodologies for the Life Cycle Cost, control and diagnostics techniques.

ELIOS (C) - PON 2012-2014

Emergent Laser fIber Optic Welded Structures

Project partners:
Consorzio CALEF, Università di Napoli Federico II -DIMPM-Centro Sviluppo Materiali SpA

The aim of the project is the development of innovative fabrication processes of newly designed complex titanium components for the aeronautical industry, usIng. fibre Laser Beam WeldIng. (LBW) to obtain near net shape components in order to reduce the buy-to-fly ratio. Realisation of prototype fiber laser station

See Project Result

VIS4FACTORY

Visual information systems for factory processes in the transport sector

Aim of the VIS4FACTORY project was to outline a set of enabling technologies based on the paradigm of advanced visualization (virtual reality, augmented reality, mixed reality, multisensory interaction) applied to the manufacturing context of the design and production of advanced materials and components for the sector of transport. In particular, it is expected to intervene in specific phases of the manufacturing company value chain, namely:
The virtual, immersive, cooperative and concurrent design The quality check of the product / material / component;
Maintenance processes Production planning, advancement and optimization;
Assembly processes.

MAC FAR

The activities of CALEF in the project concerned the following activities:
• Development of materials and technologies for the realization of the molds without the aid of the master
• Development of automated cutting techniques using power lasers
• Techniques for finishing molds for the construction of products for the pleasure shipbuilding industry
• Rapid prototyping of raw molds for the construction of articles for the pleasure shipbuilding industry
• Development of cellular metallic materials for innovative structural components
• Development of structural sandwich panels using cellular metallic materials (CALEF ENEA-BRI)
• Development of numerical models and design criteria for sandwich panels in cellular metallic material
• Titanium for the naval sector
• Development of welding techniques between metallic materials for applications in the pleasure shipbuilding industry

NEXTOWER

“PROGETTO NEXTOWER”- “Advanced materials solutions for next generation high efficiency concentrated solar power (CSP) tower systems”
https://cordis.europa.eu/project/rcn/207409_it.html;
http://www.h2020-nextower.eu/; (website)
http://www.h2020-nextower.eu/filesharer/documents/

NEXTOWER shall introduce a set of innovative materials to boost the performance of atmospheric air-based concentrated solar power (CSP) systems to make them commercially viable. In particular, tower systems are appealing for the great environmental compatibility and offer tremendous potential for efficient (electrical and thermal) power generation. Yet, their industrial exploitation has been so far hindered by limitations in the materials used both for the central receiver - the core component - and for thermal storage. Such limitations dictate maximum working temperature and in-service overall durability (mainly driven by failure from thermal cycling and thermal shocks). Improving the efficiency of a tower system entails necessarily improving the central receiver upstream and possibly re-engineering the whole systems downstream to work longer and at much higher temperature, especially in the thermal storage compartment.

CALEF participates in the European NEXTOWER project (Grant Agreement number: 721045- H2020-NMBP-2016-2017 / H2020-NMBP-2016-two-stage), with four of its consortium members:
- Italian Welding Institute (IIS),
- Research and Development Services Company srl (SRS),
- University of Calabria (UniCal)
- University of Salerno (UniSa).
CALEF was entrusted with one of the most critical tasks of the entire NEXTOWER project, which consists of the responsibility for the design, shared with ENEA, and for the assembly of the energy storage system made available by the system receiving the sun's rays.
This complex system, renamed "SOLEAD", represents an absolute innovation because for the first time, in the field of solar energy production, technology based on molten salts will be replaced with that of molten lead, at the same time representing an important technological impact the experience gained by ENEA in the field of nuclear constructions (CIRCE system).
Nonetheless, in parallel with the Engineering activities, jointing practices for the welding of all the critical components and materials of the SOLEAD system will be studied and developed.
The technical problems, in fact, impact heavily on the compatibility between containment materials and the interface with the molten lead which will reach operating temperatures higher than those normally explored in III and IV Generation plants where the main task to be carried out is that of cooling fluid.
The welded samples made and optimized will be characterized in the laboratory. The results will represent the basis for the definition of the guidelines to be adopted as a pre-normative reference for the experimental demonstrator SOLEAD and its future developments.

Finally, CALEF will have to guarantee the functionality of the SOLEAD instrumentation and its final installation at the CIEMAT site in Almeira, Spain. And at the CIEMAT site in Almeira, Spain.

OK-INSAID

PROGETTO OK-INSAID ARS01_00917
“Operational Knowledge from Insights and Analytics on Industrial Data”

Durata (mesi) 30; Data Inizio 01/07/2018;
Costo Progetto Quota CALEF 703.520€; di cui : Ricerca Industriale 442.280 € , Sviluppo Sperimentale 261.240 €

Coordinator Engineering Ingegneria Informatica S.p.; Partners: CRF-POLIBA

OK-INSAID offers scientific, technological and application innovation thanks to the introduction of Big Data Analytics in the industrial context, helping to redesign production processes and business models, to achieve a change of pace in the creation of digital services for industry. OK-INSAID recognizes the potential of data coming from productive realities, which are still under-exploited: data are potentially available, but companies do not have enough skills to extract the value, sometimes hidden, contained within them. For this reason, OK-INSAID will adopt and advance state-of-the-art technologies, defining new data driven approaches. OK-INSAID also proposes a new approach to analytics, based on the coordination, collaboration and synchronization of existing ones at cloud and edge level, thanks to a reference architecture and its implementation, aimed at developing new hybrid analytics Cloud-edge for Industry 4.0. Specifically, the innovations introduced by the project are:
• New models and methods for the acquisition and integration of industrial data from numerous heterogeneous sources, to create industrial data spaces at the enterprise level;
• New algorithms and data science methods for the generation of value and operational knowledge from big data from the aforementioned sources.
The focus will be on real-time and near-real-time analytics, with descriptive, diagnostic, predictive and prescriptive analysis methods;
• New industrial analytics services, obtained by integrating the algorithms developed in applications that exploit the distributed model of processing and analysis of industrial data space data;
• Advanced methods for the security of industrial data, aimed at assessing possible vulnerabilities (e.g. violation or theft) of industrial data and implementing adequate protection measures and countermeasures;
• Advanced methods for visualizing data aimed at providing users with ideas, value and operational knowledge extracted from the available data. The results include new user interfaces for wearable devices, personal mobile devices, augmented / virtual reality, etc. The OK-INSAID approach, the reference architecture and its implementation will be tested and validated in the operating environments provided by AVIO, SACMI, CRF / FCA.

.READ MORE (DOWNLOAD)

DOWNLOAD: Presentazione_OK-INSAID_con_grafici.pdf

ARIA

PROGETTO ARIA- ARS01_00882
“Active Responsive Intelligent Aerodynamics”

Durata (mesi) 30; Data Inizio 01/04/2018;
Costo Progetto Quota CALEF 1.424.760€; di cui : Ricerca Industriale 1.359.200 € , Sviluppo Sperimentale 65.560 €

Coordinator CENTRO RICERCHE FIAT S.C.p.A; Partners: ENEA-UNICAL-UNISAL

The project intends to develop new integrated systems, based on the use of shape memory metal alloys, capable of continuously and actively implementing surface morphing that affect the aerodynamics of motor vehicles. The aim is to verify the possibility of obtaining benefits in terms of performance and consumption from the use of intelligent materials (SMA) to create active composites, capable of changing their shape when subjected to specific inputs in response to different operating conditions. In order for the surface of the vehicle to take on certain configurations according to the stimuli sent, it is necessary to appropriately choose the materials constituting both the matrix and the reinforcement, to design and optimize the configuration of the composite and to develop an appropriate technological process. Therefore, the research activity foresees an in-depth study and experimentation phase for the identification and characterization of the most suitable materials for the production of active composites. The configuration of the active composite surface will require the development of a robust methodology of design and optimization based on the achievement of the pre-established functional requirements and validated by means of the experimental numerical comparison.
The production process of active composites will also be developed both during the production of the specimens and during the realization of the demonstrators.
The demonstrators will be designed on the basis of an implementation strategy of the ARIA technology on the car taken into consideration as a case study, for the achievement of predetermined performance objectives. The technique of integrating shape memory systems into the vehicle will be developed and the results obtainable will be ascertained from track and wind tunnel tests. Motor vehicles (cars and light commercial vehicles) are one of the major industries in terms of production value and number of employees in the less developed regions, with important investments in research and development (R&D) in Campania. At the same time as the expected impact on the product and on the macro-reality constituted by the production plants of vehicles and components, an impact is also expected in terms of an increase in specialist and employment know-how in Campania..

READ MORE (DOWNLOAD)

DOWNLOAD: Presentazione ARIA con grafici[4285].pdf

THALASSA

PROJECT ARS01_00293
THALASSA “TecHnology And materials for safe Low consumption And low life cycle cost veSSels And crafts”
(MIUR- PON R&I 2014-2020)

Capofila:DISTRETTO NAVTEC (NAVTEC : DISTRETTO TECNOLOGICO TRASPORTI NAVALI)
Durata (mesi) 30 Data Inizio 01/06/2019
Costo Progetto Quota CALEF (K€) 600,0
Soggetti Attuatori :ENEA - UNICAL – UNISA - POLIBA

The aim of the project is to study and develop innovative technologies and advanced materials to be used in the shipbuilding industry, such that they can meet the needs of the companies involved in the project and the challenges posed by EU, national and regional programs in terms of transport. smart, green and integrated maritime. The approach is based on two key elements: sustainability, associated with performance, and the life cycle. Materials, construction systems and processes, on which the project focuses, will be subjected to an innovation process that wants to overcome the current technological level. The result of OR1 is the “excellent” joint - resistant, safe and comfortable - capable of connecting hybrid structures, in terms of materials used (polymer / metal, composite / metal) and components (hull / bulkhead), aimed at reducing the ship weights and disassembly. Innovative production processes will be adopted: laser etching / texturing, clinching, self piercing riveting, curing, bonding. The result of OR2 is the adoption in the shipbuilding industry of welding systems and, in particular, of friction stir welding to create bimetallic connections (aluminum / steel). The result of OR3 is the eco-friendly and bio-sustainable composite. New reinforcement fibers (natural vegetable / mineral and hybrid) will be studied, but also new thermosetting resins will be formulated, more sustainable than those in use. In addition, processes for the recycling of composites based on thermosetting resins will be studied. The result of OR4 is the formulation of hydrophobic and antifouling coatings with biocidal action to be used on components and fittings of boats of different nature and profile of use and thick coatings for protection from flames and acoustic / thermal insulation. Finally, the result of OR5, is a system for monitoring the health status of ships in terms of assessing corrosive processes and the consequent structural damage aimed at increasing MTBM. These results will be validated and demonstrated thanks to the involvement of the companies that will test the solutions proposed on vehicles and components and to the use of a vehicle created under the PON R&C 2007/2013 by NAVTEC. What has been studied and developed will have a considerable value for the companies involved in terms of visibility and competitiveness (e.g. cruise shipbuilding), with an expected economic and above all employment return.

ACTIVITY OR1.1 CALEF (ENEA): Laser texturing for the improvement of adhesion.
Aim of activity: Surface fusion and / or vaporization caused by focused and pulsed laser radiation. Purpose, in general: • Modification of wettability • Reduction of the friction coefficient • Creation of geometric patterns in molding • Improvement of adhesion in bonding Instrumentation most frequently used: • Short pulse laser (10-9 ÷ 10-15 s) , high fluence (≈1 J / cm2), wavelength <= 500 nm, average power contained • Galvanometric optics for scanning In this activity, instead, a typical setup of laser welding processes was used: • CW laser, modular (max 5 kHz), high average power (4.2 kW); • Specialized optic for wobbling welding • Opportunity to evaluate the application of industrial standard devices (reliability, efficiency, productivity) the only texturing welding equipment

SAL 2 (Oct. 2019 – Jen. 2020) (PDF)
Contributi: • Politecnico di Bari • Università della Calabria • Università di Salerno