DISTOPIA - Distorting the Aerospace Manufacturing Boundaries: Operational Integration of Autonomy on Titanium

航空航天领域的经典设计和制造模式导致了很高的购买-飞行比率，因为几乎90%的原材料通过锻造坯料的减材加工变成了废料。即使是采用传统制造路线的昂贵的先进工程钛合金也是如此。通过机械加工和其他加工程序报废大部分原材料也会导致交货时间增加，这福尔斯落后于当前航空航天制造业的复杂要求。DISTOPIA项目将通过开发一种自动化、具有成本效益的线进给DED增材制造（AM）和修复方法来解决这些问题-扭曲航空航天制造边界，使用具有增强的机械性能的新型金属线成为可能;与传统方法相比，增材制造（AM）提供了一种替代的视角，特别是在原材料的利用，复杂的设计能力，缩短了交货时间，降低了成本。Wire-fed DED，通常被称为WAAM，是AM技术之一，它通过利用弧焊来确保高生产率，同时通过使用工业机器人和焊接源等传统设备来保持合理的成本。DISTOPIA专注于WAAM未来的一个关键方面，由于AM的当前趋势是开发新材料，与为常规制造路线开发和优化的材料相比，新材料提供上级生产率和材料性能。这一点，再加上先进的过程监测和控制系统的使用，将为航空航天工业的技术优化和适应开辟道路。这些将克服WAAM DED方法的关键进入障碍，有助于使该方法更容易获得和接受。成本将在两个主要方面显著降低：1.通过仅需要零件质量所需的线材2。通过消除对库存的需求-通常超过200万个备件，用于多种飞机设计。这些节省将提高欧洲航空航天工业的全球竞争力，并支持可持续发展目标。通过DISTOPIA，将在3个航空航天制造/维修示例中进行演示，并考虑对其他行业（采矿，能源，化学加工）的适用性。

The classical design and manufacturing paradigm in aerospace leads to a high buy-to-fly ratio because almost 90% of raw materials are turned into scrap, through subtractive machining from forged billet. This is the case even for costly, advanced engineering Ti-alloys where traditional manufacturing routes are employed. Scrapping most of the raw material through machining and other processing routines also results in increased lead times which falls behind the complex requirements of the current aerospace manufacturing landscape.The DISTOPIA project will address these problem - distorting aerospace manufacturing boundaries - by developing an automated, cost-efficient wire-fed DED additive manufacturing (AM) and repairing method, made possible using novel metallic wires with enhanced mechanical properties; combined with implementation of a full digital twin model of the process.Additive manufacturing (AM) provides an alternative perspective compared to the conventional methods, particularly regarding the utilisation of raw materials, complex design capabilities, decreased lead times and costs as a combined effect. Wire-fed DED, commonly referred to as WAAM, is one of the AM techniques which ensures a high rate of productivity by leveraging arc welding while also maintaining reasonable costs through the use of traditional equipment like industrial robots and welding sources.DISTOPIA focuses on a critical aspect for the future of WAAM, as current trend on AM is development of new materials that offer superior productivity and material properties compared to the ones developed and optimised for conventional manufacturing routes. This, combined with the use of advanced process monitoring and control systems will lead the way for the optimisation and adaptation of the technology for the aerospace industry. These will overcome critical barriers to entry for the WAAM DED approach, helping to make the approach more readily available and accepted.Cost will be significantly reduced in two main ways:1. By requiring only wire material as needed for part mass2. By eliminating the requirement for stock - typically over 2 million spare parts across multiple aircraft designs.These savings will increase the global competitiveness of the European aerospace industry and support sustainable development goals. With DISTOPIA this will be demonstrated for 3 aerospace manufacturing/repair examples, as well as considering applicability to other sectors (mining, energy, chemical processing).