Researchers have recently developed a new concept, FAST-forge, in high value manufacturing which could lead to a more cost effective and sustainable production process in the aerospace industry. It was developed by engineers at the University of Sheffield and funded by Innovate UK. The technology will provide engineers with more design flexibility, and potentially lead to improved buy-to-fly ratios: currently for some aerospace components, 90% of the forged titanium alloy is machined away to waste material.
Availability of titanium is key to the UKâs ever-growing aerospace manufacturing industry, second in size only to the US. Primary aerospace companies such as Rolls-Royce, Boeing and Airbus have long term supply agreements with titanium producers, such as TIMET and VSMPO-AVISMA. Working with UK industry partners Metalysis, the UKâs Defence Science and Technology Laboratory (DSTL), Advanced Forming Research Centre (AFRC) and Safran Landing Systems, the group of researchers are working to transform rutile sand to novel titanium alloy aerospace components in three steps; production of titanium powder from the rutile sand, field-assisted sintering technology and a one-step forging process.
Jean-Philippe Villain-Chastre / Safran Landing Systems said âAs world leader in aircraft landing and braking systems, weâre highly interested in the prospects and benefits of such a breakthrough technology. In this project, we are bringing our state-of-the-art machining, testing capabilities and expertise in qualifying aerospace grade materials to ensure that the titanium components which will be manufactured under this new process become a benchmark for the industry.â?