The low cost, high quality The low cost, high quality g q yg q yprocess route for titaniumprocess route for titanium

Frank ParenteFrank ParenteFrank ParenteFrank ParenteAdvanced Manufacturing ParkAdvanced Manufacturing Park

2,000 years of material 2,000 years of material innovationinnovationinnovationinnovation

• Advanced Manufacturing Park (AMP) is in the Sheffield City Region.

− History of innovations over 2,000 years

− Crucible steel manufacturingCrucible steel manufacturing

− Invention of stainless steel

• Pioneering low cost, high quality g , g q ytitanium processing.

AMP L ti SlidAMP L ti SlidAMP Location SlideAMP Location Slide

• 90 minutes from Manchester International Airport with direct flights to 6 US citiesflights to 6 US cities.

• 25 minutes from Robin Hood International airport with links to Europe

• Center of the UK road network

40 i t f il f i ht li k• 40 minutes from rail freight link direct to Europe

VisionVisionVisionVisionThe Advanced Manufacturing Park vision is:g

– To enable companies to exploit knowledge and innovation in materials technology with strategic emphasis on Titanium

– To gain and maintain a repetitive advantage

– Create a financial and technology business model that has attracted world class advanced manufacturing companies likeattracted world class advanced manufacturing companies like Boeing and Rolls Royce

– To provide a business model that protects Intellectual Property Rights

Advanced Manufacturing ParkAdvanced Manufacturing ParkAdvanced Manufacturing ParkAdvanced Manufacturing Park• World class R&D Associations in Titanium generating

repetitive advantage• Regional strengths – workforce and supply chains • A prestige location – education/countryside/cultural historyA prestige location education/countryside/cultural history• Flexible facilities including green-field, multi-client and

incubation• Unbeaten funding support for inward investors• Dedicated account management• Excellence in investor support• Excellence in investor support

Industry SectorsIndustry SectorsIndustry SectorsIndustry Sectors

AMP MAIN R&D GROUPSAMP MAIN R&D GROUPSFaster, Better, Less ExpensivelyFaster, Better, Less Expensively

• The development and implementation of novel manufacturing p p gtechniques to deliver significant improvements in lead times, quality and costs of manufactured products

• Delivered via leading Research and Technology Organisations i h l i i l ll iwith complementary expertise, uniquely all on one site:

• High-performance machining; additive net-shape f t i d lli d i l timanufacturing; modelling and simulation

• High integrity castings; specialised alloy formulation; rapid manufacture; modelling and simulation p ; g

• Materials joining; additive net-shape manufacturing; energy efficient materials processing

• Application of composites and advanced materials

AMRCAMRCBoeing & University of SheffieldBoeing & University of Sheffield

• Global Research Centre devoted to the Research and Development of• Global Research Centre devoted to the Research and Development of new means, methodologies, tools and techniques machining and manufacturing technology for titanium.

• Some key partners are:

Titanium MachiningTitanium MachiningTitanium MachiningTitanium Machining

Titanium Fan Disc

Machining times:

Original Target Achieved

Per slot: 36mins 18mins 1.5mins

Per disk: 26hrs <2hrs

Result: Machining time reduced by anResult: Machining time reduced by an order of magnitude!

Messier Dowty Messier Dowty 787 Ti Landing Gear787 Ti Landing Gear

• Project to machine landing gear components from new grade of titanium alloy

O i i l ti 54 hOriginal time = 54 hrsTarget time = 27 hrs

Achieved time = 11 hrs

• AMRC is reducing machining times in major OEMs -g g j(Rolls Royce, Messier Dowty and Smiths have reduced machining times by a factor of 5-40)

• Assisting UK Suppliers to win major orders –Messier Dowty won $2 billion contract for 787

Shaped Metal DepositionShaped Metal DepositionShaped Metal DepositionShaped Metal DepositionShape Metal Deposition (SMD) is an additive process that grows parts

Work with Rolls Royce led to

by depositing layers of molten metal into complex, fully dense, thin walled shapes with no waste using 3D CAD / CAM models.

Work with Rolls-Royce led to production of a large demonstration piece modelled on the scale and geometric complexity of a large civilgeometric complexity of a large civil engine intercase component.

Sh d M t l Di itiSh d M t l Di itiShaped Metal DispositionShaped Metal Disposition

Formula OneFormula OneFormula OneFormula OneCti work with many of the top Formula One and World Rally Championship Teamsand World Rally Championship Teams

Cti has the ability to cast titanium components for gearbox, suspension and braking systems to the high qualitybraking systems to the high qualityrequired by the teams, within the tight timescales needed to develop prototypes and the final componentsand the final components

Friction Stir WeldingFriction Stir Weldinggg

• TWI patented process - 1991TWI patented process 1991• Low distortion• High strength

V l d ti t t ith l i i• Volume production status with aluminium• Successful laboratory welding of titanium

F i ti Sti W ldiF i ti Sti W ldiFriction Stir WeldingFriction Stir Welding

CAMTeCCAMTeCCAMTeCCAMTeC• The thermal expansion and electro-

chemical potential mis-matches between carbon composites and traditional metals, typically steel, al mini m and magnesi m arealuminium and magnesium, are further driving the demand for titanium structures. This is perhaps most evident in the Boeing 787 whereevident in the Boeing 787 where titanium is replacing aluminium for metallic structural components.

• Partners include : Boeing; Smiths Group; Messier Dowty; Rolls Royce; Cytec; Cincinatti Machines;Cytec; Cincinatti Machines; Brookhouse Composites; Renault F1

R i l T h lR i l T h lRegional Technology Regional Technology Infrastructure for TitaniumInfrastructure for TitaniumInfrastructure for TitaniumInfrastructure for Titanium

Center of Excellence for TitaniumCenter of Excellence for Titanium• Metalysis is developing a high capacity, low energy continuous

production process for titanium

• CTI is investing heavily in vacuum refining and thin wall casting

• Active Metals is developing nano-particulate alloys from titanium

• TWI is expanding the friction stir welding process to include titanium

• The Sheffield University / Boeing AMRC is demonstrating y g gexceptional advances in the machining of titanium.

• Technicut and Lomas are developing cutting tools that are in world-wide demand for working with titaniumworld wide demand for working with titanium.

• IFA has a capacity to forge and extrude very large titanium components

• Pro-Roll has the capability to produce rolled titanium bar product to very exacting tolerances

Working with the AMPWorking with the AMP

Funding Support in SouthFunding Support in SouthFunding Support in South Funding Support in South YorkshireYorkshire

• Companies investing in South Yorkshire can benefit from significant levels of funding assistance

• Grant support is targeted at companies in the Advanced Manufacturing and Materials Technology sector

• The AMP Team will provide expert assistance in identifying all potential sources of funding assistance, and presenting a strong case for the level of assistance required to allow thestrong case for the level of assistance required to allow the project to go ahead

Be at the leading edgeBe at the leading edge• If you want to:

– Cast titanium– Weld titanium– Machine titanium

• To the highest quality,

– Faster – More efficiently– With less waste

And all in one place– And all in one place

• Then you need to be on the AMP !

frank.parente@advancedmanufacturingpark.com