DIGITISATION AND OPTIMISATION OF UK METAL COMPOSITE FIBRE FOR IMPROVED ECONOMICS
Lead Participant:
TISICS LIMITED
Abstract
Fibre reinforced Metal Matrix Composites have extensive applications in high growth industrial sectors such as space and aerospace, key to the UK's economic growth and industrial strategy for exports. These lightweight materials offer 30% weight savings in direct replacement parts and up to 70% weight saving where system designs can be optimised. The UK has a strong history in the technology and the core supply chain from raw materials to final products.
TISICS is the only integrated fibre and metal composite manufacturer worldwide and has extensive experience in developing component and process technologies for a wide range of applications including:
* Aero-engines: Lighter, higher operating temperature components reduce fuel burn.
* Aircraft landing gear: Lighter, higher stiffness gear reduces fuel burn and titanium composites offer an alternative to chrome or cadmium plated steels.
* Satellite pressure vessel: lighter, near net shape propellant and pressurant tanks reduce system mass and half lead time which will be advantageous for constellation satellites.
* Space robotics and structures: Lighter, more compact systems are key to space exploration and in-space servicing.
* Energy: Lighter, more robust steam turbines will increase energy generation efficiency, reducing emissions.
* Automotive: longer term high production volume economics will allow MMCs to offer lighter systems capable of reducing emissions from combustion engines or range extension for electric vehicles.
This project builds on the previous work aimed at the development of a world leading silicon carbide fibre production facility for MMCs. In order to industrialise this technology further development is needed to bring manufacturing maturity and production economics, of which the reinforcing silicon carbide fibre is a significant factor, to the necessary level for inclusion in space and aerospace platform designs.
To address this TISICS development strategy for its fibre (since completing its development in 2014) has involved some initial process automation and digitisation and improving reactor component designs. The next steps to be addressed in this project are for:
* further process digitisation for real time process monitoring and diagnostics. Achieving a more economic process and blueprint for a larger facility by extending the use of digital sensors for process control and in-process monitoring to lead to reliability gains in start-up and to extend batch production output
* improved feedstock supply control and conversion rates via modelling and redesigning the feedstock supply, capture and recycle systems
* modelling and designing waste management solutions. This project will address the major costs influences.
TISICS is the only integrated fibre and metal composite manufacturer worldwide and has extensive experience in developing component and process technologies for a wide range of applications including:
* Aero-engines: Lighter, higher operating temperature components reduce fuel burn.
* Aircraft landing gear: Lighter, higher stiffness gear reduces fuel burn and titanium composites offer an alternative to chrome or cadmium plated steels.
* Satellite pressure vessel: lighter, near net shape propellant and pressurant tanks reduce system mass and half lead time which will be advantageous for constellation satellites.
* Space robotics and structures: Lighter, more compact systems are key to space exploration and in-space servicing.
* Energy: Lighter, more robust steam turbines will increase energy generation efficiency, reducing emissions.
* Automotive: longer term high production volume economics will allow MMCs to offer lighter systems capable of reducing emissions from combustion engines or range extension for electric vehicles.
This project builds on the previous work aimed at the development of a world leading silicon carbide fibre production facility for MMCs. In order to industrialise this technology further development is needed to bring manufacturing maturity and production economics, of which the reinforcing silicon carbide fibre is a significant factor, to the necessary level for inclusion in space and aerospace platform designs.
To address this TISICS development strategy for its fibre (since completing its development in 2014) has involved some initial process automation and digitisation and improving reactor component designs. The next steps to be addressed in this project are for:
* further process digitisation for real time process monitoring and diagnostics. Achieving a more economic process and blueprint for a larger facility by extending the use of digital sensors for process control and in-process monitoring to lead to reliability gains in start-up and to extend batch production output
* improved feedstock supply control and conversion rates via modelling and redesigning the feedstock supply, capture and recycle systems
* modelling and designing waste management solutions. This project will address the major costs influences.
Lead Participant | Project Cost | Grant Offer |
|---|---|---|
| TISICS LIMITED | £284,563 | £ 199,194 |
Participant |
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| INNOVATE UK |
People |
ORCID iD |
| Stephen Kyle-Henney (Project Manager) |