Norsk Titanium Components AS (NTiC) and Spirit AeroSystems, Inc. have reached a significant milestone in a multi-year collaboration for Direct Metal Deposition (DMD) technology. Together the companies have achieved technology readiness level six (TRL6), demonstrating the ability to meet aerospace material requirements.
NTiC has developed a “near-net-shape” manufacturing technology that enables titanium components to be built up close to the final shape using inexpensive titanium feedstock instead of a large titanium block. The process reduces waste, uses less energy and is significantly faster.
“This is a significant achievement for the aerospace industry,” said Spirit AeroSystems Director of Technology Development, Bill Smith. “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 per cent.”
The process, developed by NTiC at their Eggemoen facility outside Hønefoss, Norway, transforms titanium wire into complex components that are up to 70 – 80 per cent complete. Traditional titanium machining may utilize only 10 per cent of the raw material with 90 per cent of it discarded as waste. In addition to significantly reducing the amount of raw material used, the NTiC process provides much shorter lead times, design flexibility, and reduces the overall cost to machine parts.
“The aerospace industry is by far the largest and most demanding titanium segment in the world, and achieving TRL6 is a major milestone,” said CEO of NTiC, Jon André Løkke. “We are very pleased with the cooperation and support we have from Spirit and we are now eager to complete the qualification process and start producing parts for the aerospace industry. This is also great news for our overall marketing efforts as material quality fit for aerospace also will be of interest to oil & gas, defense and other industries that require premium quality titanium components”
Spirit and NTiC have worked closely to develop NTiC’s DMD process for producing Ti6Al4V material for use in commercial aerospace applications. The milestone confirms the capability of NTiC’s material to meet the requirements for aircraft structural components. 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.