AMRC to use wire arc additive manufacturing for aerospace

The project aimed to develop the use of wire arc additive manufacturing (WAAM), a production process used to 3D-print metal parts that uses an electric arc to melt a metal wire, depositing layers of melted metal on top of each other, until a desired 3D shape is created.

WAAM is used in multiple industrial sectors, including energy, defence, construction and automotive, to produce large and complex structural components, whilst reducing the need for assembly and joining technologies, as well as waste material.

The process has been used for repair and remanufacturing purposes in the aerospace industry already, which has the advantage of greater supply chain flexibility, enabling on-demand production in small quantities, and saving time and costs.

AMRC tested the utilisation of WAAM to construct a demonstrator storage tank for liquid hydrogen using an aluminium alloy for use in the aerospace sector.

Hydrogen is a highly sustainable energy carrier and is considered by many as pivotal for achieving climate neutrality in the EU by 2050, particularly for industry and heavy transport. However, challenges around how to store hydrogen limit its full potential, according to the research team.