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Development of Aero Engine Component Manufacture using Laser Additive Manufacturing

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.
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Coordinator

ROLLS-ROYCE PLC

Address

Buckingham Gate 62
Sw1e 6at 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)

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ASOCIACION CENTRO DE INVESTIGACION EN TECNOLOGIAS DE UNION LORTEK

Spain

MTU AERO ENGINES GMBH

Germany

PRATT & WHITNEY RZESZOW SPOLKA AKCYJNA

Poland

EU Contribution

€ 34 490,50

INDUSTRIA DE TURBO PROPULSORES S.A.U.

Spain

EU Contribution

€ 150 578

MTU AERO ENGINES AG

Germany

EU Contribution

€ 404 000

LPW Technology Ltd

United Kingdom

EU Contribution

€ 165 592,80

SAFRAN HELICOPTER ENGINES

France

EU Contribution

€ 263 871,50

GKN AEROSPACE SWEDEN AB

Sweden

EU Contribution

€ 172 746

TWI LIMITED

United Kingdom

EU Contribution

€ 978 099,45

FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.

Germany

EU Contribution

€ 726 323,50

ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS

France

EU Contribution

€ 327 316,25

LORTEK S COOP

Spain

EU Contribution

€ 323 880,60

BCT STEUERUNGS UND DV-SYSTEME GMBH

Germany

EU Contribution

€ 393 828,80

HOGSKOLAN VAST

Sweden

EU Contribution

€ 544 233

FREDERICK RESEARCH CENTER

Cyprus

EU Contribution

€ 178 436,60

Project information

Grant agreement ID: 266271

Status

Closed project

  • Start date

    1 January 2011

  • End date

    31 December 2014

Funded under:

FP7-TRANSPORT

  • Overall budget:

    € 7 062 175,83

  • EU contribution

    € 4 886 561

Coordinated by:

ROLLS-ROYCE PLC

United Kingdom