RECYCLING
To extend the usage of the metal and LPBF powders (LPBF is a technique used for metal 3D printing), as well as allow re-use of thermoset prepreg and thermoplastic production waste in aerospace sector, the SUSTAINair project aims to investigate:
- The impact of SHM sensors on recycling
- Near-net shape metallic process development as well as near-net additive manufacturing of metallic components
- Inhouse recycling from cast housing production scrap
- Inter-recycling of wrought (solid form) or cast (liquid form) alloys
- Upcycling of thermoset prepreg production waste material
- Upcycling of thermoplastic production waste
- Characterisation of new recyclate materials
- Life Cycle Assessment in compliance with ISO14040:2006
The outcomes are new up- and recycling technologies to reduce Buy-to-Fly (BTF) ratio, saving substantial amounts of virgin material and with it associated costs.
Additionally, the SUSTAINair project aims to cut down on waste-streams in manufacturing by enabling inhouse reuse of scrap i.e. runner from casting, used Additive Manufacturing (AM) powder, uncured thermoset remainder of prepregs; thermoplastic short fibre feedstock.
SUSTAINair outcomes:
- Up to 75% cost reduction versus current 1st life composite materials
- 10-20% weight decrease
- Up to 100% recyclability versus negative effects from downcycling, pyrolysis or landfill of current thermoset FRPs (Fibre-reinforced plastic).
SUSTAINair incorporates two key enabling technologies for recycling of aerospace-grade materials:
Hybrid recycled laminate materials, enabling highly efficient variable thickness
The processes explored in SUSTAINair should produce a novel hybrid thermoplastic upcycled material. This will be a homogeneous, laminate material from chopped/shredded recycled materials in combination with CFRP face layers of virgin Uni-Directional (UD) or fabric materials.
The resulting highly efficient processes and applications with variable thickness and great specific strength and stiffness properties aim to achieve at least double the flexural strength compared to state-of-the-art recycling options.
Improvement of processing conditions in Laser Powder Bed Fusion (LPBF) and powder recycling strategies for enhanced titanium powder life cycles
SUSTAINair will develop and integrate process improvements for the inert gas handling and impurity monitoring in the LPBF process,one of the techniques used for metal 3D printing, next to L-DED, also used by SUSTAINair.
This will improve reusability of titanium powder and increase BTF ratio by using it 6x versus current one time use in the aerospace industry.
DLR, DTC, AIT-LKR and INVENT will lead efforts related to up- and recycling of materials, with contributions by other project partners.
Joanneum Research will lead the efforts on the impact of SHM sensors on recycling, with contributions by other project partners.
NLR will lead the Life Cycle Assessment with contributions by other project partners.