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“It’s a different technology to the metal powder-based additive manufacturing, or ‘3D printing’ technologies that most people are familiar with,” said Chris Dent, Head of Research and Technology at Lockheed Martin UK, Ampthill.
WAAM is differentiated by its ability to deposit materials at high rates (several kg/hour) and to produce large structures (for example, several metres in each dimension). A broad range of materials is available from steel, titanium, aluminium and refractory metals. Using WAAM technology, the highly skilled team at Lockheed Martin uses innovative techniques to support everything from the initial concept phase, right through to the production of primary mechanical structures.
The high deposition rates and the material properties achievable with WAAM really are game changing. The process can create large structures in short time frames, and with similar properties to wrought materials. The use of WAAM has enabled Lockheed Martin to reap considerable cost and schedule savings.
Dent continued: “We’ve been working on WAAM since 2012 with our own manufacturing cell on-site in close partnership with Cranfield University, which invented the WAAM process.
“We’ve developed a number of parts for some of our space programmes, including a demisable fuel tank, and various other structures, as well as developing concepts for parts on our armoured vehicle programmes for the British Army.”
The parts developed at the Ampthill site for the company’s space programmes are at a range of technology readiness levels (TRLs). “It’s really exciting to see some of the research and development that we’ve worked on over the years turning into actual items.
“We’ve also developed test fixtures using generative design software and manufactured fixtures that can only be created using AM. Some of these are quite large but we have achieved mass savings without sacrificing stiffness, both of which are important for vibration testing, for instance,” said Dent.
Lockheed Martin continues to work on maturing the technology in an industrial setting to achieve consistency, repeatability, qualification and certification. A key element has been developing the supply chain for the wire consumables. Dent commented: “Continuing to build a solid network of supplier partnerships is integral to the future development of this capability.”
AM is not only revolutionising the way products are developed and manufactured for use on Earth, but the process is enhancing capabilities and technology that is being transferred into space applications.
Working in partnership with the UK Space Agency (UKSA) and the European Space Agency (ESA), Lockheed Martin UK has been developing a demisable fuel tank. Traditionally these tanks, which are made from materials such as titanium, have a habit of surviving re-entry – this can create a potential hazard to those on the ground. Lockheed Martin’s aluminium fuel tank disintegrates in the atmosphere during re-entry – this is really important, especially as the number of spacecraft in orbit increases rapidly over the next few years, we need to ensure that all satellite and launcher debris are safely disposed of.
Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.