The Challenge:
Overcoming Titanium Supply Chain Issues and Traditional Manufacturing Lead Times
The Titanium (Ti6A14V) electronics housing is one of a family of housings integral to a mine-detecting sonar system on a mine countermeasures vessel. With typical housing constructed using a multi-staged process of forgings, welding, and machining, the lead time of some larger components was in the region of 24 months. This led Thales to explore Wire Arc Additive Manufacturing (WAAM) as an alternative.
The use of Titanium has two distinct drawbacks, and with it an opportunity to look for an alternative manufacturing method as part of the MOD’s project TAMPA.
With heightened tensions across the globe, the supply chain for titanium is becoming increasingly more difficult.
Titanium is an expensive material, and with high percentages of a large billet being machined away to produce this geometry, conventional manufacturing is not cost-effective or environmentally sustainable.
A crucial aspect of this challenge was to ensure the material achieved the 10% elongation to maintain the housing’s integrity under a mine shock load, necessitating robust qualification of the part for use.
The Solution:
Production of Qualified, Mission-Critical Components using the Wire Arc Additive Manufacturing (WAAM) Process
As part of Project TAMPA, the solution involved validating initial processing parameters through test walls and material property verification. This allowed for the subsequent production of similar parts within the component family, using the Wire Arc Additive Manufacturing (WAAM) process to create a near-net shape with 4mm of stock for machining.
Titanium processing was conducted in an inert atmosphere for safety and quality, followed by roughing and 5-axis machining on a Hermle centre to achieve final tolerances. The final Ti64 electronics housing was delivered with a First Article Inspection Report (FAIR), including dimensional inspection, mechanical testing and non-destructive testing.
How do we ensure the best part can be qualified for use?
- Wire Arc Additive Manufacturing (WAAM) produces a near-net-shaped ‘billet’ to replace forging or casting.
- Geometry and material requirements dictate the optimal toolpath used for the WAAM manufacturing process.
- Alongside the WAAM component, a reference part was produced for tensile testing and validation.
- Non-destructive testing (NDT), such as radiography, is conducted on the WAAM component and reference part to check for porosity and voids as per customer requirements.
Discover how WAAM is helping create a more efficient and resilient manufacturing route for critical titanium components
Discover how Thales used Wire Arc Additive Manufacturing (WAAM) to overcome titanium supply chain challenges and reduce reliance on traditional manufacturing methods with lead times of up to 24 months.
Developed as part of MOD Project TAMPA, the project demonstrates how WAAM can produce qualified, near-net-shape titanium components for mission-critical defence applications, combining additive manufacturing with precision 5-axis machining and rigorous inspection and testing.
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