Novel internal finishing of complex, safety critical structures.

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The internal surfaces of complex structural or functional components can have quite a poor surface finish. This is particularly true of components made by additive layer manufacturing (ALM). In many cases the roughness can initiate fatigue cracks which undermines the reliability and life of a component. On external component surfaces, finishing can be done with simple mechanical polishing. For internal surfaces polishing is more difficult and requires a more complex approach. This project will evaluate a new approach to internal polishing of complex structures which uses a novel polishing media which can be manipulated electromagnetically from the outside of the component. Fluctuating magnetic fields will be used to manipulate the polishing media, providing consistent, predictable polishing to all internal surfaces of a component. This has great potential as a new process for achieving highly polished internal structures of complex components with surface finish and fatigue properties comparable with conventionally processed material. At present a reliable, adaptable internal surface finishing technology is one of the major technical hurdles restricting the widespread use of complex internal structures in aerospace applications. If successful this new technology will enable designers to fully realise the potential of ALM, allowing unparalleled geometric freedom for a design and manufacture of complex components with hitherto impossible levels of detail and functional integration.The project objectives will include:1. Development and characterisation of the polishing media 2. Evaluation of surface finishing process variables3. Modelling electromagnetic characteristics of the structure & polishing media interaction4. Technology demonstration via a custom test rig