Spirit AeroSystems Inc., Wichita, Kan., and Norsk Titanium Components AS, Norway, have reached a significant milestone in a multi-year collaboration for direct metal deposition technology. They developed an additive manufacturing technology that enables titanium components to be built up close to the final shape using titanium feedstock instead of a large titanium block. The process reduces waste, uses less energy, and is significantly faster.
Together the companies have achieved technology readiness level six (TRL6), demonstrating the ability to meet aerospace material requirements. “This is a significant achievement for the aerospace industry,” said Bill Smith, Spirit AeroSystems director of technology development. “Titanium is an expensive and difficult material to manufacture. By having near-net-shape product forms, Spirit is able to reduce costs. Additionally, this direct from digital process can reduce the time to market for new parts by at least 60 percent.”
The process transforms titanium feedstock into complex components that are up to 70 – 80% complete. Traditional titanium machining may utilize only 10% of the raw material with 90% discarded as scrap. In addition to significantly reducing the amount of raw material, the process provides much shorter lead times, design flexibility, and reduced overall machining cost.
Spirit and NTiC are currently working under a cooperative agreement to complete qualification of the process that will lead to widespread aerospace application. The qualification effort is expected to be complete in 2014 allowing structural designers to use the DMD process for new and existing airplane programs.
