To create a UK powder supply chain optimised to facilitate increased adoption of AM for structural metal parts in the Aerospace sector. The project will allow for joint understanding and cooperation via the Aerospace Supply Chain alongside other market sector adopters. Developing, testing and recording powder in use to create control and quality standards not currently existing in the supply chain process critical to allow for the industrialisation of AM. The project will look to close gaps and market failures whilst exploiting the future demands of AM in Aerospace whilst enhancing competitiveness in the market.

A collaborative ATI project has been developed to address a number of challenges currently facing the aerospace industry. The collaboration is led by Spirit AeroSystems (Europe), the largest independent Tier 1 “design and build” supplier to the aerospace industry whose main UK facility is located next to Prestwick International Airport. The partners are Aeromet International and the University of Sheffield Advanced Manufacturing Research Centre (AMRC), the former being a world leader in the production of Aluminium and Magnesium sand castings and Aluminium investment castings. The AMRC is a High Value Manufacturing (HVM) Catapult focusing on developing manufacturing solutions for industry across a wide range of sectors. The overarching aim of the Programme is to help sustain UK aerospace jobs and ensure that the UK consolidates its position as the second largest global aerospace supplier currently with a market value and share of £24 billion and 17%, respectively. The scope of the technical work will align with both the Protect and Exploit element of the Governmental PEP model developed by the Aerospace Growth Partnership AGP as part of the industrial strategy and has the following key objectives: -manufacturing process improvement of legacy products to facilitate rate increase requirements for the industries OEMs; -creation of opportunities for on-shoring of aerospace component work packages to maintain the long-term security of the UK manufacturing base; the development, testing and validation of complex integrated manufacturing processes associated with composite aircraft wing technology. -The ATI initiative provides Spirit and Aeromet with the opportunity to benefit from financial support to develop their technologies for use on current on future commercial aircraft. AMRC will help the industrial partners de-risk the technical and financial barriers through the collaborative development of the new technologies.

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

Roll Royce Controls and Data Services Limited will lead a project team with Aeromet International PLC and Birmingham University to design, develop and demonstration test innovative aluminium alloy composites with enhanced high temperature capabilities. The development of these alloys will enable near-net shape design, reduced product manufacturing cost and energy use, and extended service intervals. It will also stimulate novel, high performance, fuel efficient lower mass pump designs and provide future capability for aircraft engine core mounting. The project team has the experience, ability and skills to optimise manufacturing techniques, alloy composition and high temperature mechanical properties for early application in high value product markets (i.e., aerospace) and longer term applications in high volume markets (e.g. automotive). This capability significantly enhances the project’s impact and exploitation potential

The essence of this proposal is to introduce innovative aluminium casting alloys and related processing know-how for the manufacture of advanced highly stressed large structures as found in aerospace, automotive and similar sectors. This innovation is expected to bring about a step improvement from current manufacturing methods and fully aligns with the TSB’s High Value Manufacturing strategy. A resource efficient, cost effective approach will displace expensive machine from solid methods ensuring the UK builds a strong competitive and sustainable position in these important global markets. The approach has been enabled by a patented new aluminium alloy –A20X – which has been developed and characterised by Aeromet International plc, the lead partner in this project. A20X has demonstrated characteristics which are far in excess of today’s commonly used high performance alloys; namely, high isotropic strength, double the fatigue life and properties that ensure levels of integrity not possible to achieve using current generation alloys. Application of this high value manufacturing technology is strongly supported by leading companies in the aerospace and automotive sectors seeking weight and cost reductions. The project sets out to develop and derisk the manufacture of large structures by developing and evaluating innovative casting and post casting processes using a range of virtual toolsets validated by test pieces based on real applications. Practical work will be underpinned by fundamental metallurgical characterisation and development and validation of models to optimise liquid metal and solidification behaviours.