New technique has potential to dramatically cut aircraft component production costs.

Johannesburg – Airbus, South Africa’s CSIR and Aerosud have agreed to partner on a research project to test the application of titanium powder-based Additive Layer Manufacturing (ALM) for the fabrication of large and complex aerospace components.

The titanium ALM project is the latest in a series of Airbus Research & Technology partnerships established under a 2006 agreement with the Department of Science & Technology.

It will see Airbus, supported by EADS Innovation Works, cooperating with Aerosud (the South African aerostructures manufacturer) and the CSIR’s National Laser Centre (NLC).  Together, they will test and evaluate this radical new approach as it is applied to producing larger-scale titanium parts at high speed by using the NLC’s expertise in high-powered lasers and laser-based manufacturing expertise.

If successful, the project could have significant cost and environmental efficiency ramifications for airlines, aircraft operators, the aerospace and other manufacturing industries in addition to boosting South Africa’s minerals beneficiation strategy.

“ALM involves forming an object from powder, which is arranged in layers and fused by high-speed lasers.  It is a process completely devoid of bulk machining, cutting and welding thereby minimizing waste and optimizing the manufacturing process.  It’s like printing in 3D,” explained the CSIR’s Mr. Hardus Greyling, project coordinator of project Aeroswift at the CSIR.

Aerosud and the CSIR NLC have been developing the innovative ALM approach under the Dept of Science & Technology-funded Aeroswift project.   Initial proof-of-concept studies were carried out a few months ago and based on the results a decision was made to construct a full scale prototype system to demonstrate the technology. This technology will allow the production of large geometrically complex items. “Typically focusing on parts which are prohibitively expensive or impossible to make using traditional methods,” said Aerosud Managing Director, Dr Paul Potgieter.

“There is no doubt that ALM is changing the small-scale component manufacturing landscape and with Airbus joining the partnership, it will be possible to test and evaluate the manufacturing process on large components for passenger jetliners,” explained Dale King, Airbus Senior Manager International Research & Technology Projects.

“The above-mentioned projects have been supported through research and technology development funding grants of approximately R65 million over the last six years from the Department of Science and Technology” said Mr Beeuwen Gerryts, Chief Director at the Department of Science & Technology.

The project is central to South Africa’s national titanium beneficiation strategy, which aims to transform the country from an exporter of raw materials to an exporter of semi-finished or finished goods which can be sold at a premium compared with the material in its raw state.

Current manufacturing relies on traditional milling and machining where components are cut and carved out of a metal billet, a process that typically sees up to 95 percent of expensive raw material going to waste.   In contrast, the ALM technique minimizes material wastage by building up a component from powder, with the optimal amount of material being consumed in the process. Any powder left over can be dusted off and used again. The potential cost savings in raw materials could potentially amount to millions of dollars on every jetliner built.  In addition, the weight savings are likely to result in significant cost savings and reduced emissions through lower fuel consumption.

About Airbus’s Research & Technology Network

Since the introduction of jet engine aircraft, the air transport industry has achieved enormous improvements in economic efficiency and the environmental performance of aircraft, eg. in the past 40 years, the industry has cut fuel burn and CO₂ emissions by 70%, NO_x emissions by 90% and noise by 75%.  During that time, innovation has been a key driver in Airbus’s success.

Environmental and safety considerations are an integral part of Airbus’s activities and a key priority in developing new techniques, products and processes.  Through innovation and out-of-the-box thinking, Airbus will continue to ensure that air travel continues to be one of the safest and most eco-efficient means of transport.

Through its Research & Technology (R&T) network, Airbus is working with governments, industries, research institutes and universities around the world, including South Africa, to find the best solutions that can deliver significant improvements, step-changes, in efficiency and performance and that will benefit and contribute to the growth of the industry on a global scale.

Airbus launched its South African R&T programme in 2006 under an agreement with the Dept of Science & Technology and the Dept of Trade & Industry.  Airbus’s South African R&T projects are coordinated through the DTI’s National Aerospace Centre.  Airbus has forged partnerships with Stellenbosch University, WITS University, University of Cape Town and various units of the CSIR, working on a variety of projects.

About the Department of Science and Technology

The Department of Science & Technology (DST) provides funding supports to a range of niche and high-potential new industrial development initiatives in order to exploit novel South Africa technologies or technological capabilities. It is anticipated that these initiatives will create entire new industries or industry sectors leading to long-term economic growth, the creation of jobs, new technology spin-offs, and increased foreign exchange earnings. Other initiatives supported included the development of titanium metal powder, new fluorochemicals-based projects, and biocomposites.