Challenges of manufacturing an layout optimised EB-PBF component for aerospace flight

The challenges for manufacturing AM components for critical aerospace applications are numerous, reducing the amount of innovation that can be applied to the industry. This presentation will describe the challenges that the MTC encountered during the EWIRA Clean Sky 2 project, which aimed to manufacture an aileron hinge bracket using electron beam powder bed fusion (EB-PBF) for a test flight. Challenges surrounding machine stability, sensitivity of the AM process and surface finishing of complex components will be discussed, with a view given on where the future state needs to focus.

A presentation by Nick Cruchley, Senior Research Engineer at Manufacturing Technology Centre (MTC).

About Nick Cruchley
As an Advanced Research Engineer at the MTC he works to understand and develop all areas of metal additive manufacturing for industry. He is actively working in processing new materials in LPBF, optimising thermal post processing and benchmarking new and novel additive techniques.

He is also leading the MTC’s efforts in the EWIRA Cleansky 2 project, which aims to re-design a critical aerospace component for additive manufacture and validation of the manufacturing process. Therefore a large focus of mine is validation and qualification of materials manufactured through additive manufacturing and in particular, electron beam melting (EBM).

About Manufacturing Technology Centre (MTC)
MTC was established in 2010 as an independent Research & Technology Organisation (RTO) with the objective of bridging the gap between academia and industry – often referred to as ‘the valley of death’.

It represents one of the largest public sector investments in UK manufacturing and, after four years of planning and a 16 month build, the facility opened at Ansty Park in Coventry at the end of 2011.

In December 2011, there were 16 industrial members, 44 staff and just a few key pieces of equipment in the ‘workshop’.
Over the following seven years the MTC’s rapid growth has seen the expansion of our campus with the construction of three more facilities, including the opening of the Advanced Manufacturing Training Centre and the National Centre for Additive Manufacturing.

Our role has also increased to cover not only R&D but also Training, Advanced Manufacturing Management and Factory Design. We now have over 700 talented employees working with us.
During this time we have helped hundreds of companies across a range of industries and over 100 of them have become members of the MTC.

Our clear vision is to inspire Great British manufacturing on the global stage. We provide integrated manufacturing system solutions for customers large and small, across sectors as diverse as automotive, aerospace, rail, informatics, food & drink, construction/civil engineering, electronics, oil & gas and defence.

Nick Cruchley will be speaking at the 2021 edition of the Aerospace 3D Printing Conference.

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