Process reduces waste in titanium manufacture
Traditional methods for manufacturing large titanium aerospace parts can waste 95 per cent of raw material, but an international consortium is commercialising a new technique that promises little or no scrap.
The process, shaped metal deposition (SMD), manufactures components by building them up from welded wire − typically titanium alloy or aerospace-grade steel − which reduces the machining needed to achieve final component design.
Rolls-Royce patented and first demonstrated the technology several years ago. As reported in The Engineer in 2008, researchers involved in the international Rapid Production of Large Aerospace Components (RAPOLAC) project have been working on developing a way to automate the entire process, as the system requires continuous monitoring and control by a human operator.
The results of the three-year project involving eight academic and industrial partners from the UK, Belgium, Italy and Argentina have been pronounced a success.
Project manager Rosemary Gault said the team now has a proof of concept SMD cell running at Sheffield University’s Advanced Manufacturing Research Centre (AMRC). They have produced test parts for six different aerospace companies and have also been approached by companies from other sectors, including medical and motorsports.
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