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

DISTOPIA - 扭曲航空航天制造边界：钛合金上的自主运营集成

• 批准号: 10086469
• 金额: $ 128.75万
• 依托单位: AUTHENTISE
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2024
• 资助国家: 英国
• 起止时间: 2024 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=10086469
• 关键词: DISTOPIA; Distorting; Aerospace; Manufacturing; Boundaries

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).

航空航天领域的经典设计和制造模式导致了高的购买与飞行比率，因为几乎90%的原材料是通过从锻造的坯料中减去加工而变成废料的。即使是采用传统生产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提前期的增加，这远远落后于当前航空航天制造环境的复杂要求。Destopia项目将解决这些扭曲航空制造边界的问题-通过开发自动化、成本高效的线馈DED添加剂制造(AM)和修复方法，使用具有增强机械性能的新型金属线；结合工艺的全数字孪生模型的实施。与传统方法相比，添加剂制造(AM)提供了另一种视角，特别是在原材料的利用、复杂的设计能力、缩短的交付期和综合效果下的成本。送丝DED，通常称为WAAM，是AM技术之一，通过利用弧焊确保高生产率，同时通过使用工业机器人和焊接源等传统设备保持合理的成本。DISTOPIA专注于WAAM未来的一个关键方面，因为AM目前的趋势是开发新材料，与传统制造路线开发和优化的材料相比，提供更高的生产率和材料性能。这一点，再加上先进的过程监测和控制系统的使用，将引领航空航天行业技术的优化和适应。这些将克服进入WAAM DED方法的关键障碍，有助于使该方法更容易获得和接受。成本将通过两个主要方式显著降低：1.只需要部分质量所需的线材2。通过消除对库存的要求--通常是多个飞机设计的200多万个备件。这些节省将增加欧洲航空航天工业的全球竞争力，并支持可持续发展目标。这一点将在3个航空航天制造/维修实例中进行演示，并考虑到对其他部门(采矿、能源、化学加工)的适用性。