Periodic Reporting for period 3 - MMTech (New aerospace advanced cost effective materials and rapid manufacturingtechnologies)
Reporting period: 2018-05-01 to 2019-04-30
The goal of MMTech was the sustainable introduction of γ-TiAl into aerospace applications through the achievement of a number of primary objectives:
• Reduce the production cost of γ-TiAl parts by 45%
• Reduce production time of γ-TiAl by 55%
• Reduce maintenance costs by 8%
• Target component weight savings of 20-50% using γ-TiAl
• Reduce raw material use over the life of the component by 20%
• Extend component service life by 15%
To address the objectives, the use of near-net production and consideration of different phases of the manufacturing cycle were investigated and the following technical and commercial challenges addressed:
• The production of powders with stable physical properties
• The reduction of rapid manufacturing costs
• The improvement of machining processes
• The development of multi-scale models of the manufacturing process chain
• Integration of MMTech-nologies in real, industrial components
- High-energy-ball-milled, low-cost, gamma titanium powders - these are available for sale
- Increased knowledge on requirements for AM of gamma titanium which will has been published, and will be used in consultancy
- A machine for milling gamma titanium parts, including different machine options (spindle, toolholder, connections, lubricants, filtration, vibration monitoring and control systems) which is available for sale
- Machining methods for gamma titanium (parameters, tools, lubrication strategies) which have been published
- A reliability and maintenance simulation to optimise machine availability which has been integrated with the machine tool
- Milling tools to reduce chatter -available
- Self-adaptive process control - published and used in consultancy
- A damping table - may be patented
- The ARES damper for milling vibration suppression - intend to patent
- Integrated multi-scale models of the process chain - used in consultancy
- Know-how related to the production of aerospace and automotive components in gamma titanium - used in production
In the final year, the focus moved towards manufacturing and testing the demonstrators. A virtual pilot line was created which demonstrated each result; this has been posted on the website and used at events. Partners have attended a number of events and trade shows targeted at the aerospace and automotive sectors leading to a similar number of items in trade and popular publications.
Reduce maintenance costs by 8%: The reliability and maintainability analysis of the machine tool will reduce maintenance costs by 10%. The use of gamma titanium alloys in place of nickel super-alloys will reduce wear and hence maintenance, whilst increasing component service life. The manufacturing parameters affect the part microstructure which in turn significantly affects the mechanical properties of the final part. The models will indicate the correct parameters to produce optimum microstructures. It was not possible to carry out industrial tests over long enough timescales to determine overall maintenance reduction but partners estimate that by moving to gamma titaniumm they will reduce component maintenance by 9% for shafts and 40% for blades.
Component weight savings of 20-50%: The selected material variants have a density of 50% that of Nickel superalloy materials, ensuring weight savings around 50%. Further savings can be made through the use of AM and the increased design freedom this brings. Partners found weight savings of 42% - 48% depending on the manufacturing route chosen.
Reduce raw material by 20%: powder production yield was increased to 90-95%, offering a 20% saving in raw material compared to other methods of powder manufacture. Near-net production will reduce the amount of raw material required; this is part dependent. The milling tools to prevent chatter and the self-adaptive process control will reduce the number of parts scrapped during machining. Partners found a reduction in raw material use of 5%, 28% and 80% when considering an additive manufacturing production route. When laser-cutting their component, the raw material savings were in excess of 80% for one part.
Extend component life by 15%: modelling and parameter optimisation will allow process parameters to be tailored to create durable, fault-free parts to extend service life. The use of AM will allow novel geometries to be made, reducing areas of stress concentration and will also reduce the number of welds. The improved surface finish achieved through the active damping system will increase service life by 15%. After extensive testing, one partner estimates that the service life of near-net components will improve by 180%; they experienced no change for laser-cut parts. Other partners estimated a service-life increase of 25% - 40%.