Sovereign manufacturing reliable defence structures by 3D metal printing and structural health monitoring

Project Summary

3D-printed metals that can reliably withstand extreme environments are an ongoing need for Defence and industry. Printing-induced internal defects and stresses in the metals deteriorate their strength, resulting in weakened structural integrity.

This project will enable the development of advanced manufacturing processes. The team will carry out laser printing, heat treatment and wire arc additive manufacturing to gain a deeper understanding of fatigue behaviour and surface quality of metals. A variety of tests will be undertaken including micro- and macro-scale non-destructive evaluation of internal defects and stresses, as well as thermal damages in the processed metals. A statistical analysis will be used to determine the influences of processing parameters on multiscale internal damages and stresses, surface roughness, and fatigue life/strength of the processed metals.

The outcomes will enable (a) DSTG to understand the fatigue behaviour and surface quality of laser-printed stainless steel and Inconel; (b) develop heat treatment to improve their fatigue life; and (c) AML3D to commercialise reliable WAAM-made copper nickel aluminium (CNA) alloys.