China3D printingOn August 16th, the Advanced Forming Research Center (AFRC) of the University of Strathclyde, Scotland, and Airbus Defense and Aerospace have launched a project that may apply additive manufacturing to the production of fuel tanks. The project between the two partners aims to provide resources for the production of propellant tanks for aviation and aerospace in the UK. Independent welding research organization TWI has been invited to help decipher which method is best for competitive production tanks. The European Space Agency (ESA) is funding the project.
Airbus Product and Research and Technology (R&T) Manager Renato Bellarosa commented: “Propellant “tanks” are currently a key strategic project that we must purchase from Germany or the United States. We are working hard to rebuild this project and hope to make them in the UK. We have done this in the past, but without success.
We still have independent supply chain processes in the UK, and we need to integrate them into manufacturing. “
Metal forming v superplastic forming v additive manufacturing
The focus of AFRC’s ESA support project is to be able to produce a space propellant storage tank that is as close to the net shape as possible. Our idea is that this will reduce processing time and material waste, thereby achieving economically competitive production.
Composed of two hemispherical domes and cylindrical parts, the components of the fuel tank are usually forged, heat-treated, machined, and then welded together. They are very thin structures, and milling them to the correct thickness creates a lot of waste. At the same time, they must be strong enough to store propellants under high pressure for up to 25 years, and to withstand the return journey from low earth orbit (LEO) back to earth.
An example of a space propellant tank outside the ESA LISA Pathfinder. Photo courtesy of ESA
Dr. Jill Miscandlon is the head of AFRC’s fuel tank project. “Airbus will combine their own research experience with our research and decide on the selected technology.” Dr. Miscandlon said, he detailed the role of the university in the project. “This could be metal forming, superplastic forming or additive manufacturing processes-all of which will bring the tank part close to the net shape.
The key to the project is the shorter lead time for manufacturing components and the waste of lower cost materials. This is crucial for titanium alloys that cost up to $60 per kilogram, depending on the alloy type and manufacturing route. “
Benefit from the UK and other regions
The project adds to Scotland’s growing influence in the global aerospace sector. As the development home of the UK’s first spaceport, Sutherland, the Scottish Highlands, young space exploration companies are striving to establish a foothold in the country. In early 2019, British aerospace company Orbex chose to locate its headquarters in Forres, close to the developing spaceport. The Sutherland Spaceport will also be the launch site for the Rocket Lab Rutherford launch rocket.According to China3D printingThe network understands that Glasgow, the port city of Scotland, has more small satellites built than anywhere else in Europe.
In addition to the benefits to the local economy and the wider supply chain in the UK, Airbus DS also sees the export potential of the program. Bellarosa added: “Our overseas customers are important players in the satellite manufacturing industry, and we believe they will be interested in this new manufacturing method.”
Dr. Jill Miscandlon, Director of the Fullerk “Tank” project at the Advanced Forming Research Center at the University of Strathclyde.Photo from Strathclyde University
Professor Keith Ridgway, Executive Chairman of AFRC, said: “This is a great project that highlights the benefits of combining advanced manufacturing research with the growing aerospace industry in the UK.It also draws on Strathclyde’s focus on space innovation, through its technology and innovation center development in the Glasgow Urban Innovation District, to unite researchers and high-growth companies with technology and creative start-ups to work”.
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