Context | Radome Ring in Additive
MBDA chooses Sòphia High Tech for innovative additive manufacturing activities on the INVAR material
Additive Manufacturing can match the needs of the Aerospace and Defense field, enabling the production of increasingly lightweight components with high mechanical qualities and using increasingly efficient materials. This also makes significant contributions to environmental benefits and the sustainability of the aerospace industry.
In fact, reducing the weight of aerospace parts translates into lower CO2 emissions during flight, reducing the associated costs. Not only weight, but also mechanical properties, material performance, and, above all, component reliability are important in the aerospace industry. Metallic superalloys enable the production of parts with exceptional mechanical/thermal characteristics that are more efficient and reliable. Furthermore, by properly optimizing part geometries, they ensure an exceptional cost/quality balance.
MBDA, has chosen to undertake, in team with Sòphia High Tech, a process validation and qualification program for additive manufacturing applied to mechanical components made by INVAR: a metal alloy composed primarily of iron and nickel, characterized by a very low coefficient of thermal expansion (CTE). This property makes it ideal for applications requiring dimensional stability in the presence of temperature variations.
The metal 3D printing process chosen as the enabling technology by MBDA and SOPHIA is SLM [Selective Laser Melting]. This process, belonging to the LBPF [Laser Powder Bed Fusion] domain, uses high-power lasers to melt and solidify metal powder layer by layer. The laser follows the 3D model, heating and melting the metal powder to form a monolithic component.
The pioneering target achieved by MBDA and SOPHIA is the development of the INVAR alloy using the SLM process, guaranteeing repeatable and scalable process parameters, in order to allow its use in the missile sector on serial mechanical components.
Targets | Radome Ring in Additive
MBDA is a European multinational group, a world leader in complex weapons systems, employing 18,000 people. MBDA is the leading manufacturer of missiles and defense technologies for the air force, navy, and land-based armed forces. The company’s headquarters are located in Le Plessis-Robinson, France, while MBDA Italy and MBDA UK are in Rome/Naples and Stevenage, respectively. MBDA is controlled under equal corporate governance rules by Airbus Group (37.5%), BAE Systems (37.5%), and Leonardo (25%).
Sòphia High Tech, certified according to the AS/EN9100 Aerospace Quality Standard, focuses on the design and production of mechanical parts and assemblies for the aerospace and defense sectors. The production department uses cutting-edge technological processes such as Metal Additive Manufacturing (3D printing) and CNC Machining (milling/turning) to create complex components, both in shape and geometry, and installations on spacecraft. The added value at Sòphia lies precisely in the integration, and therefore the expertise, of both processes to obtain finished parts.
MBDA entrusted Sòphia for the setup, development, qualification, and manufacturing of the Radome Ring using Additive Manufacturing.
The Ring was realized by Sòphia High Tech using Selective Laser Melting technology, made of INVAR alloy. This aerospace component, installed on rockets, is highly complex in terms of geometry and size and has always been produced using CNC Machining, starting from a custom casting. Therefore, the work carried out in synergy between the companies involved the selection and development of the INVAR36 alloy process parameters using SLM technology and the sizing of the heat treatment (specifically for INVAR36) to ensure the tensile and thermal properties of the 3D printed material (as built).
All the necessary testing and qualification activities were carried out to validate both the process and the new material, obtained through additive manufacturing. The characteristics are also improved compared to the casting process. To achieve mechanical tolerances, the machining parameters (different from those for the INVAR material processed through casting) were also qualified, leading to the qualification of new tools for CNC machining of the 3D-printed component.
Benefits | Radome Ring in Additive
By introducing this new process (ALM + CNC), MBDA achieves significant benefits, including:
- Reduction of waste (due to a more controlled and optimized process, starting from the creation of the 3D printed material)
- Reduction of production times (having developed a near-net-shape 3D printed component, a less impactful machining time is guaranteed)
- Reduction of costs (as well as the process chain)
- Reduction of environmental impact (by working with energy-efficient production processes and also qualifying the post-printing powder reuse process)
For this innovative activity, the companies have earned the coveted 1 Star Innovation Award, promoted by MBDA for the evaluation of all innovation projects.
To ensure this approach (unique in the industry), Sòphia High Tech has made (and continues to make) significant investments to guarantee a “turnkey” product, from concept design to manufacturing, integrating the delicate testing and qualification process of aerospace parts in accordance with relevant regulations. For over 12 years, Sòphia’s manufacturing department has been using the most cutting-edge technological processes (ALM and CNC machining) to produce metal alloy aerospace components, both for the structural and propulsion field.
