Experts from Fraunhofer IAPT are working on non-destructive testing
In a collaborative project led by Airbus Aerostructures, partners from industry and research are working on innovative metal technologies. Fraunhofer IAPT is participating through a subproject on additive technology and is contributing to material savings in aerospace metal manufacturing by further developing non-destructive testing (NDT).
In a collaborative project led by Airbus Aerostructures, partners from industry and research are working on innovative metal technologies. Fraunhofer IAPT is participating through a subproject on additive technology and is contributing to material savings in aerospace metal manufacturing by advancing non-destructive testing (NDT).
Additive manufacturing reduces material waste
Current metal manufacturing processes in the aerospace industry meet performance targets. However, their high material and energy consumption fails to meet today’s requirements for economic efficiency and environmental sustainability. For example, door perimeter structures are currently mostly milled from solid plates in a time- and cost-intensive process. Additive manufacturing can help avoid this enormous amount of material waste.
Increasing the efficiency of 3D printing for industrial use
The widespread industrial use of 3D printing as an efficient production method is hindered by high testing costs and low productivity. Additionally, complex, separate process chains for various joining methods and energy-intensive curing cycles in adhesive technology limit production rates.
The focus of the META consortium project, led by Airbus Aerostructures, is therefore on
- the industrial maturation of additive manufacturing processes
- advanced sheet metal forming
- optimized bonding and surface technologies.
A modular overall concept for door perimeter structures serves as an integration platform for the individual technologies.
Non-destructive quality testing for titanium test specimens
Direct Energy Deposition (DED) and a productivity-enhanced laser powder bed fusion (LPBF) process are used for high-stress aerospace components. An innovative, non-destructive quality inspection of additively manufactured test specimens aims to reduce the demand for raw materials, energy, and chemicals for titanium components produced via additive manufacturing.
In a subproject of META, the Fraunhofer IAPT team is working on two non-destructive testing (NDT) technologies for this purpose:
- Indentation testing
- Density testing
To detect poor component properties early on in the future, the researchers are building on current measuring devices and further developing the hardware. Experiments characterize the reliability of the new measurement technologies. For example, experts at Fraunhofer IAPT are performing CT scans and developing evaluation algorithms.
Savings of over 20% in titanium and up to 90% in aluminum
The quantitative goals of the overall project include reducing the use of raw materials—specifically, over 20% for titanium and up to 90% for aluminum in monolithic components. At the same time, energy costs in manufacturing—such as in autoclave processes—are to be reduced by up to 50%, and production rates are to be increased through automation and shorter lead times.
The Fraunhofer IAPT’s contribution supports all of these goals.
Technology leadership in aviation aims to secure German locations
By combining environmental benefits with enhanced competitiveness, the collaborative project makes a significant contribution to sustainable aviation. The initiative aims to establish technology leadership for German locations to secure their position in current and future aircraft programs.
