Large engineering structures like turbines, bridges or industrial machinery are still manufactured by traditional processes such as forging, casting or by machining from solid blocks. These processes do not allow local control of material properties to achieve a specific function like anti-corrosion or hardness. To meet the functional specifications, engineers must operate within a limited range of design options, with high “buy-to-fly” ratios and long lead times. Unlike any other metal AM technology, wire arc additive manufacturing (WAAM) produces fully dense metallic structures with no porosity. WAAM is also unbeatable in terms of production times, making it uniquely suited for large and functionally demanding engineering structures. In Grade2XL, we will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large scale structures. The high printing rate of WAAM, combined with the ability to control material properties down to the nanoscale, will allow us to build strong and durable engineering structures. Grade2XL will deliver multi-material products of superior quality and performance, cut lead times by up to 96% and enable massive cost savings for the maritime and energy industry, as well as for industrial machinery. These outputs will rapidly roll out to other sectors with similar key performance indicators and become an attractive investment opportunity for SMEs. This project will strengthen Europe’s capacity to drive manufacturing innovation globally and withstand growing competition from Asia.

The decarbonisation targets of the shipping sector by IMO are extremely challenging and require active measures as soon as possible. ENGIMMONIA comes with solutions that focus on two main pillars: i) promote the global introduction of alternative fuels (ammonia), ii) transfer to maritime sector clean energy technologies robustly demonstrated for terrestrial application (e.g. Waste heat recovery, renewables etc). ENGIMMONIA will indeed study the benefits of using a carbon-free fuel like ammonia (that in any case could have a GHG impact due to N2O emissions that should be properly treated by an EATS to be developed in ENGIMMONIA under AUTH/DTU supervision) in vessel engines also coupling its benefits/performances with other clean energy technologies like: (1) waste heat recovery solutions based on ORC and adsorption chiller for the production of electricity and space cooling respectively, (2) renewables integration on board thanks to the installation of PV composite surface easily installable on vessel structural parts , (3) on board fuel/energy/heat management optimization via real time Energy Mangement System; towards the creation of ENGIMMONIA polygeneration energy hub. Targeting long term full decarbonization of shipping sector, ENGIMMONIA will capitalize previous R&D initiatives that already tested some of these technologies for terrestrial application, moving them to marine sector also from a regulatory/business point of view under RINA coordination, as a naval classification body. To do so technologies will be demonstrated at TRL>5 in real scale engines (MAN) and on board of three vessels: an oil tanker (FAMOUS), a shipping vessel (DANAOS) and a ferry (ANEK) thus proving their replicability on board of different type of vessels. To guarantee ENGIMMONIA innovations wide acceptance, maritime sector’s key players are involved (C-JOB, MAN, RINA-C etc.) while other will interact as stakeholders, also supporting IMO and IACS initiatives at policy/regulatory level.

The M²ARE project develops and demonstrates a novel process for “Maritime Methanol”, a new grade of low-cost green methanol based on biogenic CO2 and renewable H2, to support the needs of the global shipping sector to reduce their CO2 emission. The highlights of the M²ARE project: Assessment and qualification of bio-CO2 from different sources (biogas, bioethanol, pulp & paper, combustion, …) for its feasibility in the methanol synthesis, thus increasing the feedstock base for Maritime Methanol. An improved methanol process using a new reactor system based on process intensification and a simplified methanol purification will be demonstrated. The new process is uniquely suited to convert bio-CO2 compositions with fluctuating H2 supply to flexible grades of Maritime Methanol which will be further optimised in its composition and validated through a series of engine tests. A digital model of the whole value chain from CO2/H2 to the maritime fuel will be developed to de-risk the technology and boost its scale-up by assessing and optimizing different geographical scenarios as basis for the deployment roadmap. M²ARE is committed to deliver by mid 2027 a European “Maritime Methanol” process (at TRL 7) providing >80% CO2 emission reduction compared to fossil maritime fuels and >10% TCO savings compared to state-of-the art green methanol technologies. M²ARE consists of a powerful and capable consortium with diverse expertises around the value chain: Air Liquide as world-leader in methanol technology, MAN as world leader for methanol-fueled maritime engines and Maersk as the world’s largest shipping company will provide industrial perspectives, while academic partners from Greece (CERTH), Italy (SSSA Pisa), France (LRPG) and The Netherlands (TU Delft) will contribute with unrivaled scientific expertise in catalyst testing, digital tools, reactor simulation and Life Cycle Assessment. Finally, ETA Florence will guarantee top-level dissemination of the project results.

SHARK will unlock the potential for laser texturing for the generation of functional surfaces by boosting the productivity, efficiency and flexibility of the process. This will provide the European industry with a highly robust, cost effective and environmentally friendly system that is capable of producing a broad range of functional surfaces at industrial scale throughputs, and place Europe in an unassailable lead in this key area of manufacturing. SHARK will advance laser surface texturing from the current ‘trial and error’, lab-scale concept into a highly predictable, data driven industrial approach by developing a digitally enabled knowledge management platform with a comprehensive database of process parameters and functionalities. SHARK system will be configured as an Open-platform independent of the laser source manufacturers, which for long, has been one of the main limitations for the process. SHARK’s system will be underpinned by a number of technology advances. Two laser surface texturing technologies will be developed, both based upon nanosecond fibre lasers. Pseudo Random laser texturing and Direct Laser Interference Patterning will be employed, offering complementary techniques to yield a highly flexible tool capable of delivering wide range of functional surfaces with exceptional productivity and excellent process efficiency. The project will develop surface texture predictive modelling to rapidly define key process variables required for specific surface functionalities. This will be combined with inline surface characterisation to enable rapid feedback and inbuilt quality assurance. The project will deliver the following benefits: • The capability to deliver surface functionalities into real products for less than 10% of the cost of the conventional part • Greater than 20% improvement in product performance based on the surface functionalities deployed. • Accelerated product development • Strengthened global position of European manufacturing

The project HERCULES-2 is targeting at a fuel-flexible large marine engine, optimally adaptive to its operating environment. The objectives of the HERCULES-2 project are associated to 4 areas of engine integrated R&D: • Improving fuel flexibility for seamless switching between different fuel types, including non-conventional fuels. • Formulating new materials to support high temperature component applications. • Developing adaptive control methodologies to retain performance over the powerplant lifetime. • Achieving near-zero emissions, via combined integrated aftertreatment of exhaust gases. The HERCULES-2 is the next phase of the R&D programme HERCULES on large engine technologies, which was initiated in 2004 as a joint vision by the two major European engine manufacturer groups MAN and WARTSILA. Three consecutive projects namely HERCULES - A, -B, -C spanned the years 2004-2014. These three projects produced exceptional results and received worldwide acclaim. The targets of HERCULES-2 build upon and surpass the targets of the previous HERCULES projects, going beyond the limits set by the regulatory authorities. By combining cutting-edge technologies, the Project overall aims at significant fuel consumption and emission reduction targets using integrated solutions, which can quickly mature into commercially available products. Focusing on the applications, the project includes several full-scale prototypes and shipboard demonstrators. The project HERCULES-2 comprises 4 R&D Work Package Groups (WPG): - WPG I: Fuel flexible engine - WPG II: New Materials (Applications in engines) - WPG III: Adaptive Powerplant for Lifetime Performance - WPG IV: Near-Zero Emissions Engine The consortium comprises 32 partners of which 30% are Industrial and 70% are Universities / Research Institutes. The Budget share is 63% Industry and 37% Universities. The HERCULES-2 proposal covers with authority and in full the Work Programme scope B1 of MG.4.1-2014.