The LuFo VI‑1 EFFIPEEN project, concluded on 7 August 2023, was carried out by SCHOLZ MECHANIK GmbH in close cooperation with the Fraunhofer Institute for Production Engineering and Applied Material Research (IFAM), the Zentrum für Angewandte Luftfahrtforschung (ZAL) and the additive‑manufacturing specialist AMPOWER GmbH & Co. KG. The initiative was funded under the German research programme LuFo VI‑1 EFFIPEEN and aimed to demonstrate the feasibility of Laser Shock Peening (LSP) for aircraft structural components while integrating the process into an automated production chain.
The core technical outcome was the design, additive manufacturing and post‑processing of a demonstrator part made from Ti‑6Al‑4V. Five identical components were produced by laser‑powder‑bed fusion (SLM) and subsequently consolidated by hot‑isostatic pressing (HIP). Surface analyses performed by IFAM measured key parameters such as deformation, surface roughness, hardness and residual stress after the application of the novel ablation‑confinement coating that accompanies the LSP treatment. Although the report does not publish explicit numerical values, it reports a measurable reduction in surface roughness and an increase in hardness, together with a beneficial shift in residual‑stress distribution that is expected to improve fatigue life. The LSP process was also evaluated for its compatibility with conventional machining, confirming that the treated surfaces remain suitable for subsequent cutting operations.
In parallel, the project investigated coating formulations and application methods (AP 2.2) to enhance corrosion resistance and reduce the need for environmentally harmful protective layers. The study identified several candidate coatings that could be applied after LSP without compromising the induced compressive stresses. Additionally, ZAL led the development of a non‑destructive testing (NDT) system (AP 3.3) to monitor material properties and process quality in real time, thereby enabling tighter control of the peening parameters and ensuring repeatability across production batches.
From a process‑integration perspective, the demonstrator was designed to fit into a largely automated manufacturing workflow. The project identified opportunities for cost optimisation, particularly in tool selection and cycle time reduction. By analysing the first production runs, the team projected extended tool life and improved throughput through refined machining parameters. These findings support the broader goal of extending the technological portfolio of SCHOLZ MECHANIK and potentially expanding the range of aircraft‑structure geometries that can be produced efficiently.
The collaboration structure was clearly defined: SCHOLZ MECHANIK led the overall project and coordinated the design and manufacturing of the demonstrator; IFAM handled surface characterisation and coating development; ZAL focused on the NDT system and process monitoring; and AMPOWER supplied the additive‑manufacturing expertise and executed the SLM/HIP production of the five parts. The project spanned several work packages (HAP 1–4) and was completed within the scheduled timeframe, culminating in the final report that consolidates the experimental data, process evaluations and economic assessments.
In summary, the LuFo VI‑1 EFFIPEEN project achieved a demonstrable integration of Laser Shock Peening into an automated production line for titanium alloy aircraft components, validated the process through additive manufacturing and post‑processing, and laid the groundwork for improved surface properties, corrosion resistance and manufacturing efficiency. The collaborative effort among industry, research institutes and a specialised additive‑manufacturing partner has positioned SCHOLZ MECHANIK to strengthen its market position within the Airbus supply chain and to advance the adoption of advanced peening technologies in the aerospace sector.