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Development of Aero Engine Component Manufacture using Laser Additive Manufacturing

Objective

The concept of the MERLIN project is to reduce the environmental impact of air transport using Additive Manufacturing (AM) techniques in the manufacture of civil aero engines. MERLIN will develop AM techniques, at the level 1 stage, to allow environmental benefits including near 100% material utilisation, current buy to fly ratios result in massive amounts of waste, no toxic chemical usage and no tooling costs, to impact the manufacture of future aero engine components. All of these factors will drastically reduce emissions across the life-cycle of the parts. There will also be added in-service benefits because of the design freedom in AM. Light-weighting, and the performance improvement of parts will result in reduced fuel consumption and reduced emissions. MERLIN will seek to develop the state-of-the-art by producing higher performance additive manufactured parts in a more productive, consistent, measurable, environmentally friendly and cost effective way.

The MERLIN consortia has identified the following areas where a progression of the state-of-the art is needed to take advantage of AM:

• Productivity increase.
• Design or Topology optimisation.
• Powder recycling validation.
• In-process NDT development.
• In-process geometrical validation.
• High specification materials process development.

The MERLIN consortium comprises six world leading aero engine manufacturers, Rolls-Royce is the coordinator, six renowned RTD providers and two intelligent SME’s. Impacts will include the development of high value, disruptive AM technologies capable of step changes in performance which will safeguard EU companies in the high value aero engine manufacturing field. AM will significantly reduce waste in an industry where materials require massive amounts of energy and toxic chemicals, in-process toxic chemical usage will be massively reduced, and emissions will drop because of the reduced amount of material involved.

Field of science

  • /engineering and technology/mechanical engineering/manufacturing engineering/additive manufacturing
  • /natural sciences/mathematics/pure mathematics/topology
  • /social sciences/social and economic geography/transport
  • /natural sciences/physical sciences/optics/laser physics
  • /social sciences/economics and business/economics/production economics/productivity

Call for proposal

FP7-AAT-2010-RTD-1
See other projects for this call

Funding Scheme

CP-FP - Small or medium-scale focused research project

Coordinator

ROLLS-ROYCE PLC
Address
Kings Place 90 York Way
N1 9FX London
United Kingdom
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 223 164
Administrative Contact
Keith Nurney (Mr.)

Participants (15)

ASOCIACION CENTRO DE INVESTIGACION EN TECNOLOGIAS DE UNION LORTEK

Participation ended

Spain
Address
Bo La Granja Sn
20240 Ordizia
Activity type
Research Organisations
Administrative Contact
Josune Sarasola (Ms.)
MTU AERO ENGINES GMBH

Participation ended

Germany
Address
Dachauer Strasse, 665
80995 Muenchen
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Stephan Servaty (Mr.)
PRATT & WHITNEY RZESZOW SPOLKA AKCYJNA
Poland
EU contribution
€ 34 490,50
Address
Ulica Hetmanska 120
35 078 Rzeszow
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Robert Haligowski (Mr.)
INDUSTRIA DE TURBO PROPULSORES S.A.U.
Spain
EU contribution
€ 150 578
Address
Parque Tecnologico De Zamudio 300
48170 Zamudio-vizcaya
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Alfonso Alba (Mr.)
MTU AERO ENGINES AG
Germany
EU contribution
€ 404 000
Address
Dachauer Strasse 665
80995 Munchen
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Stephan Servaty (Mr.)
LPW Technology Ltd
United Kingdom
EU contribution
€ 165 592,80
Address
Keckwick Lane Vanguard House Daresbury Science & Innovation Campus
WA4 4FS Daresbury
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Carroll Philip Anthony (Dr.)
SAFRAN HELICOPTER ENGINES
France
EU contribution
€ 263 871,50
Address
Avenue Du President Szydlowski
64510 Bordes
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Francis Fabien (Mr.)
GKN AEROSPACE SWEDEN AB
Sweden
EU contribution
€ 172 746
Address
-
46181 Trollhaettan
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Jonsson Peter (Mr.)
TWI LIMITED
United Kingdom
EU contribution
€ 978 099,45
Address
Granta Park Great Abington
CB21 6AL Cambridge
Activity type
Research Organisations
Administrative Contact
Agata Surowiec (Ms.)
FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Germany
EU contribution
€ 726 323,50
Address
Hansastrasse 27C
80686 Munchen
Activity type
Research Organisations
Administrative Contact
Walter Krause (Mr.)
ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS
France
EU contribution
€ 327 316,25
Address
Boulevard Saint Michel 60
75272 Paris
Activity type
Research Organisations
Administrative Contact
Florence Thépenier (Ms.)
LORTEK S COOP
Spain
EU contribution
€ 323 880,60
Address
Arranomendia Kalea 4 A
20240 Ordizia
Activity type
Research Organisations
Administrative Contact
Josune Sarasola (Ms.)
BCT STEUERUNGS UND DV-SYSTEME GMBH
Germany
EU contribution
€ 393 828,80
Address
Carlo-schmid-allee 3
44263 Dortmund
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Claus Bremer (Dr.)
HOGSKOLAN VAST
Sweden
EU contribution
€ 544 233
Address
Hogskolan Vast
461 86 Trollhattan
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Ann-Kristin Johansson (Ms.)
FREDERICK RESEARCH CENTER
Cyprus
EU contribution
€ 178 436,60
Address
Diagorou, Era House (11Th Floor) 2
1097 Lefkosia
Activity type
Research Organisations
Administrative Contact
Loucas Papadakis (Dr.)