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买飞比，因为几乎90%的原材料都是通过锻坯的减法加工变成废料的。即使对于采用传统制造路线的昂贵、先进的工程钛合金，情况也是如此。通过机械加工和其他加工程序废弃大部分原材料也导致交货时间增加，这落后于当前航空航天制造领域的复杂要求。DISTOPIA项目将通过开发一种自动化、经济高效的线馈DED增材制造（AM）和修复方法来解决这些扭曲航空航天制造边界的问题，该方法可能使用具有增强机械性能的新型金属丝；结合实现全数字孪生模型的流程。与传统方法相比，增材制造（AM）提供了另一种视角，特别是在原材料利用、复杂设计能力、交货时间缩短和成本降低等方面。线喂DED，通常被称为WAAM，是增材制造技术之一，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关注的是WAAM未来的一个关键方面，因为与传统制造路线开发和优化的材料相比，AM目前的趋势是开发具有卓越生产力和材料性能的新材料。这与先进的过程监控系统的使用相结合，将为航空航天工业的技术优化和适应开辟道路。这将克服WAAM DED方法进入的关键障碍，有助于使该方法更容易获得和接受。成本将显著降低，主要有两个方面：1。通过只要求零件质量所需的线材2。通过消除对库存的需求-通常在多种飞机设计中超过200万个备件。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。对于DISTOPIA，这将用于3个航空航天制造/维修示例，以及考虑其他部门（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).