Development of Atomiser Nozzle Design to increase Yield (DANDY 2)

航空航天部件的附加制造(AM)为重量更轻、性能更高的部件创造了机会，这可以显著减少制造浪费(较低的购买与飞行比率)和飞机的重量。这将节省燃料，降低运营成本，减少碳排放，从而有利于我们的环境。我们预计飞机的关键部件，如机翼和机身，在不久的将来不会发生变化，但在更换对飞行不那么关键的部件方面有真正的潜力，如支架、夹具、铰链、座椅扣和家具。例如，为一架飞机生产1公斤支架，需要在制造过程中投入10公斤原材料。从工程设计的角度来看，最终的支架可能仍然含有比应用所需的金属多得多的金属。另一方面，3D打印需要的原材料投入要少得多，而且可以通过更好的点阵设计进一步生产重量最小的部件。目前的次优设计是由于传统制造的限制。当我们像AM那样以一层一层的方式制造东西时，这些限制就会减少。据我们采访过的公司称，航空航天行业完全采用添加剂制造的最大障碍之一是金属粉末的成本和可用性。AM中使用的15-45微米部分仅占产量的约40%。如果雾化喷嘴的设计可以将这一比例提高到50-60%，则价格将显著降低，可获得性增加，使其更适用于航空航天部件。Liberty粉末金属公司(项目负责人)和材料加工研究所(分包商)拥有在金属行业拥有30多年经验的员工，他们参与了基本氧气炼钢、氧枪喷嘴的重新设计，使用听力测量、物理、数学模型并与喷嘴制造商密切合作，成功地改进了钢浴的精炼，最大限度地增加了废钢熔化量，使工艺更高效、经济可行。同样的人和技能将与利兹大学一起在这个项目中使用建模和听力测量来调查改装雾化器喷嘴的可行性。该项目将有助于实现政府的[清洁增长战略][0]和[净零雄心][1]，通过减少制造航空零部件的废物来保护当代和未来几代人的气候和环境，飞机轻量化，降低油耗。[0]：https://www.gov.uk/government/publications/clean-growth-strategy[1]：https://www.gov.uk/government/news/uk-becomes-first-major-economy-to-pass-net-zero-emissions-law

Additive manufacturing (AM) of aerospace components create opportunities for lighter weight and higher performance parts which could significantly reduce both manufacturing waste (lower buy-to-fly ratio) and the weight of an aircraft. This will result in fuel savings, operational costs and decrease carbon emissions, thereby benefiting our environment.We do not anticipate a change to the crucial parts of the aircraft, such as the wings and fuselage in the near future but there is real potential in the replacement of less flight-critical parts, such as brackets, clamps, hinges, seat buckles and furnishings.To produce a 1kg bracket for an airplane, for example, requires 10kg of raw material input into the manufacturing process. From an engineering design perspective, that final bracket may still contain much more metal than is required for the application. 3D printing, on the other hand, requires far less raw material inputs and can further produce parts that minimise weight through better lattice type design. Current sub-optimal designs are due to the limits of conventional manufacturing. When we make something in layer-by-layer fashion as in AM, those constraints diminish.One of the biggest barriers to the aerospace industry fully adopting additive manufacturing, according to companies we have spoken to, is the cost and availability of the powder metal. The 15-45 micron fraction used in AM is only approximately 40% of the production. If the atomiser nozzle can be designed to increase this fraction to 50-60% the price significantly reduces and availability increases, making it more viable for aerospace components.Liberty Powder Metals (project lead) and the Materials Processing Institute (subcontractor) have employees with over 30 years experience in the metals industry who have been involved in redesigning basic oxygen steelmaking, oxygen lance nozzles, using audiometry, physical, mathematical modelling and working closely with the nozzle manufacturer to successfully improve refining of the steel bath and to maximise the amount of scrap melting to make the process more efficient and economically viable. The same people and skills together with the University of Leeds will be used in this project to use modelling and audiometry to investigate the feasibility of modifying the atomiser nozzle.This project will help deliver on the government's [Clean Growth Strategy][0] and [net zero ambition][1] to protect the climate and environment for current and future generations by reducing waste from the manufacturing of aerospace components, light weighting of aircraft and reducing fuel consumption.[0]: https://www.gov.uk/government/publications/clean-growth-strategy[1]: https://www.gov.uk/government/news/uk-becomes-first-major-economy-to-pass-net-zero-emissions-law