The objective of the proposal is to advance fundamental science in reactive porous material modeling to foster innovation on the second pillar of the work program "Leadership in Enabling and Industrial Technologies". Starting from the most advanced development done at NASA in the last decade, state-of-the-art reactive porous material models will be improved further with the contribution of expert theoreticians and implemented in a simulation tool released open source. The fundamental developments will be validated and applied to design optimization and process innovation for two industrial applications. The first one is the design of efficient and optimized thermal protection systems for space exploration vehicles (subprogram "space").The second one targets bio-hydrocarbon and bio-carbon production from lignocellulosic biomass. The biomass pyrolysis process will be studied from the wood-cell scale to the process level. The goal is to develop advanced predictive engineering tools to enable process optimization and guide innovation in progress. This second effort will eventually benefit to two "Societal Challenges" of the work program: "Energy" and "Climate action, environment, resource efficiency, and raw materials".

The main objective of the ASSALA project is to develop a methodology to predict defect generation likelihood induced by the interaction of robot inaccuracies and thermal effects during the Laser Wire Deposition (LWD) process of Titanium integrating deterministic and advanced statistical models applied on the manufacturing of new generation aero engine structures. The novel activities to carry out during the project will be based on: - The development of a tool focused on the automatic path generation applied on to robotic LWD based on 5 degree of freedom deposition. - A dynamic robot model to compensate and estimate through Monte Carlo simulation the temporal positioning accuracy. - A fast and precise computation algorithm that will allow to solve the time consuming dynamic thermo-mechanical phenomena of the solidification process based on Finite Element Modelling through model order reduction strategies. - Implementation of process monitoring (thermal and visible) and control tools (CAM correction) for the implementation of adaptive control strategies which will correct the component distortion. - Integration of the developed algorithms in a methodology to predict the failure probability based on Monte Carlo statistical tools. - Testing and validation of the developed simulation tools and implemented adaptive control strategies. ASSALA aims at contributing to achieve more efficient and robust LWD processes provided that the end effector-to-component relative distance plays a major role in the stability of the process and in the generation of defects such as cracks or flaws that can induce the rejection of the deposits due to the critical structural nature of the aero engine components.

Nowadays, mechanical production is faced with many requirements. It is necessary to perform and continuously improve the quality of manufactured products, as well as to have a good competitiveness. This dual challenge is essential to meet the growing demand of functional products and enable the development of local industrial production. The production by machining is essential; although it has existed for centuries it is always one of the processes which permits the surfaces generation with tight geometrical tolerances. Machining techniques with cutting tools are brought to always evolve and modernize themselves. In one century, productivity has increased by a factor greater than 100, with much better common quality. The considerable progress of machining has always been supported by research works, both in terms of tools and cutting material, work materials and their machinability and machining means, i.e. machines. To ensure progress, LaBoMaP Arts & Métiers ParisTech Cluny laboratory and the Saint Jean Industries company (STJI, ETI) would like to unite their skills in a joint laboratory dealing high performance machining techniques. LaBoMaP the laboratory specializes in the field of cutting and machining, and its contribution on High Speed Machining is widely recognized. The STJI Company manufactures mechanical components for automotive industry and the aerospace one. This firm fully integrates the process technologies it needs, from raw work pieces and their machining, through the manufacturing of molds and dies, and cutting tools. The scientific objective of the joint laboratory is the overall control of the machining and the development of new cutting tools ultra-hard material (including mono and poly crystalline diamond MCD and PCD) and complex geometries. This includes the life cycle stages of the cutting tool (from its design to its use through its manufacturing), and the problems of machinability and obtained surface qualities. Applications include machining aluminum, light alloys and widespread in STJI automotive business, and titanium alloys with low machinability widely uses in aerospace and energy. The research is organized in three topics: • Topic 1 - Design and production of special tools: development new tools with improved functionalities • Topic 2 - Cutting and machinability: characterization and optimization of the machining behavior, method development and prediction simulator • Topic 3 - Quality and control of machining processes: defining criteria and methodologies for process monitoring These three topics are linked together, and this organization reflects the industrial machining sequencing process. STJI firm and LaBoMaP lab have complementary skills to drive these research activities. On one hand, the LaBoMaP has strong skills in cutting and machinability of metallic materials, and secondly STJI firm has extensive expertise in the production of cutting tools, but now have no R&D activity on it. Partners are both members of the High Speed Machining Association (AUTGV) and technical frameworks of these two entities are known for several years. The desire to develop joint work is effective, and can be achieved by the proposed project by a Labcom, and furthermore we have the desire to define topics CIFRE in support / additions for the life of Labcom or later.