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Securing Australia's Future: Materials Science and Engineering in the Defence Industry
For the Australian Department of Defence, there is no greater priority than protecting the thousands of service men and women, and everyday Australians, who may be in harm’s way. The Department seeks to defend Australia’s sovereignty, national interests and promote stability in the world. But an unprecedented level of complexgeopolitical challenges is keeping the nation’s leaders on their toes when it comes to future policy and strategy. It is also prompting the Department to rethink traditional practices and fill any existing gaps in technologies or equipment for increased safety and security. As such, materials science plays a critical role in bridging this gap. Materials development and engineering supports the defence sector to meet safer, efficient, and sustainable practices in the air, land, and sea. In fact, new and advanced materials are being discovered and developed at an extraordinarily rapid pace, which has not been matched throughout history. This provides enhanced opportunities to meet any strategic or geopolitical challenges. Materials scientists believe that the next 20 to 30 years will see advanced metals and composites with greater usage in strong, lightweight structures— opening a suite of new opportunities for Australia’s defence sector. Meanwhile, the sector has identified several priority areas for future research and development, including: • Nanomaterials • Metamaterials • Materials for energy storage and generation • Multi-functional materials These areas are backed by the Federal Government’s Advanced Materials and Manufacturing report, which outlines the implications for Australia’s defence sector to 2040 and beyond. The report examines the ‘materials paradigm’, which considers the factors that allow materials to perform in specific ways. These include, but are not limited to: composition; processing; microstructure; properties; and performance. Scientists and researchers are always on the move for more efficient, safer, stronger, and sustainable materials that can provide a point of difference, enhanced security, and longevity for Australia’s defence personnel. ING Bank believes that advanced manufacturing could increase the production of locally manufactured goods and decrease global trade by 40 per cent in the years leading up to 2040. But these advances in defence science and technology are not possible without strong partnerships between stakeholders, industry professionals, research institutions and an international conglomerate of agencies. Together, these stakeholders cast theireyes and thinking towards emerging threats, and investments in modern technologies powered by materials. In practice, these collaborations and partnerships can create game changing opportunities for Australia’s defence sector.
Australian Government Linking Research with Practice
The Department of Science and Technology (DST) is Australia’s lead agency for linking science and technology to safeguard Australia’s future. The Department operates several research facilities across every Australian state and territory. The Department brings together engineers, researchers, scientists, and practitioners to deliver tailored advice and innovative solutions towards defence and national security. Around 2,300 staff are employed by DST, who are bound by core values including: operations; sustainment; future proofing; strategic research; advice to government; partnerships and outreach. DST has several capability areas that are heavily impacted by advanced materials and manufacturing, including: 1. Extreme environments: which refers to the capacity for people and vehicles to operate in a range of extreme conditions—from the depths of the sea to the bounds of space. 2. Uninhabited aerial vehicles: which can maintain a hidden surveillance of a suspected target or threat. Their speed and distance are essential for DST’s intelligence gathering and national security.
3. Power and energy storage: which analyses automated devices and
‘wireless’ sensors that may be used in the context of national security without interference. 4. Survivability: this focuses on equipment that can withstand long-term damage from the environment or intentional impacts.
This can be overcome by developing equipmentthat avoids detection, or is more durable. 5. Sensor systems: which refers to sensing systems that can detect objects. This is entirely dependent on materials and manufacturing techniques to increase the detection performance of these systems. These advances rely on materials development and technology, which has been crucial for the defence sector and human civilisation for centuries. Since the Bronze Age— where copper and bronze were the primary materials used in weapons development— which occurred around 5,000 years ago; to the modern-day processes of manufacturing iron and steel, humans have grasped technology, research, and materials to shape the world. DST is underpinned by the More, together: Defence Science and Technology Strategy 2030, which builds on Australia’s strategic advantages to position defence as a pivotal part of the nation’s security. The plan outlines DST’s commitment to advising the Federal Government and remaining a collaborative partner and an innovation integrator in the Australian policy landscape. To meet these targets, DST has a range of partner facilities and collaborations, which streamline the use and development of materials science in defence. For example, the HA Wills Structures and Materials Test Centre is an internationally recognised facility for materials testing. This state-of-the-art facility is crucial for fatigue testing structures like small coupons and aircraft components, or placing actual airframe structures in large purposebuilt rigs. Researchers and engineers understand the types of loads that are equated to flying hours. This means that when cracks appear in the test, they can estimate a time at which cracking may occur within the fleet. As such, the centre has delivered cost savings of around $400 million to the Department of Defence in relation to the Royal Australian Airforce’s (RAAF) FA-18 Hornet fleet. Through research and development, this work discovered that the aircraft could be safely flown without a major replacement of its central structure for the remainder of its planned life with the RAAF. The facility is also home to static fracture, composite, and corrosion tests that can be applied to a wide range of materials. This grants the Department of Defence with a wide range of life expectancy data and information about different components in service, and the number of hours aircraft can be flown before future work or retirement is necessary.
Hitting the Mark with Global Partnerships at Amaero
Amaero has a simple mission: solving complex problems for their customers. Since it was founded in 2013, Amaero has partnered with Monash University to commercialise additive manufacturing of metals and alloys technology. Together, the partnership services the aviation, defence, tooling, and automotive sectors. Amaero and Monash University’s strong partnership signifies a new era of materials science—where research is conducted and then put into practice. Monash University’s worldclass researchers and facilities open a new range of possibilities for the Amaero team, including 3D printing technology for the defence sector. The Amaero 3D printing technology provides enhanced manufacturing capabilities, including: • On-demand replacement of existing apparatus • Better speed and reliability • Increased quality assurance • Rapid prototyping opportunities • Reduced manufacturing times and productivity • Heavy-duty components with increased life • Reduced costs These developments offer superior durability and performance, which are critical to the defence sector. Amaero also has a facility in Los Angeles, which links the company with some of the world’s leaders in the defence, aerospace and industrial sectors. Barrie Finnin, who is the Chief Executive Officer at Amaero, said the international possibilities are endless for his company. “Amaero’s presence in North America enables it to exploit its
HA Wills Structures and Materials Test Centre. Image courtesy of Australia Government Department of Defence.
Amaero’s 3D printed jet engine.
capabilities with direct line of sight to its defence and aerospace customers, as well as on-shoring tooling manufacturing,” he said. The company is capitalising on the additive manufacturing market, which is expected to grow to $34.4 billion by 2025. “I am confident that Amaero will more than play its part,” said David Hanna, who is the Chair of Amaero. “The use of metal 3D printing is growing rapidly in the aerospace, defence, and industrial sectors with manufacturers competing to secure the latest technology to improve their product capabilities,”he explained.
End-User Driven Research at CSIRO
It is essential that Australian soldiers wear clothing and equipment that provides a high level of protection from direct and indirect chemicals. These chemicals may be biological or radioactive in nature. As such, soldiers must have access to highly specialised protective gas masks, or respirators for premium safety. Together with the Department of Defence, Australia’s leading science agency, the CSIRO, has developed the most capable respirator canister in the world. The canister aids all defence personnel by reducing the risk of exposure to toxic industrial chemicals, and hence, casualties. The materials are made from metal organic frameworks, which are made of joined metals by organic linkers. The CSIRO team has been investigating these frameworks for over a decade. The project has shown that these smart materials have a variety of applications—from carbon capture, batteries, gas storage, and even pharmaceuticals. The smart materials are filled with molecular-sized holes that can absorb, separate, store or protect chemicals. Once these frameworks are incorporated into respirator filters, they absorb toxic chemicals.
Royal Military College staff cadets in Nuclear Biological and Chemical (NBC) suits during a patrol as part of Exercise Shaggy Ridge in the Wide Bay training area, Queensland. Image courtesy of Corporal Bernard Pearson and CSIRO.
The breakthrough is already being used by Australian Defence Force practitioners under a $2.9 million deal to keep Australia’s soldiers, sailors, and air personnel safe. The CSIRO has a strategic relationship with the Department of Defence, which is designed to advance research for greater use in the defence sector, and civilian life. It covers advanced materials, manufacturing, sensors, biotechnology, and emerging technologies. It also links with the Defence Cooperative Research Centre (CRC) program, which connects researchers with end-user practitioners in the sector. The CRC has two main priorities: • Develop technologies to improve
Australia’s national security and defence • Address critical gaps in the Next
Generation Technologies fund The Next Generation Technologies fund is a Federal Government initiative, which bridges the gaps for the ‘future defence force after next.’
The defence sector heavily relies on funding and developments in research. As such, five groups were recently awarded a pool of $1.6 million for advanced materials research. The joint program combines expertise from Australia and the United Kingdom, to create innovative technologies that accelerate advanced materials integration in the defence sector. Defence Industry Minister, the Hon. Melissa Price MP, explained how the joint projects will advance Australia’s close and technical relationship with the United Kingdom’s defence industry and research institutions. “Joint research such as this not only strengthens our bilateral defence relationship but provides support and opportunities to each country’s respective defence industries to overcome the capability challenges, we face,” she said. These projects were funded by the Federal Government’s Next Generation Technologies Fund. The first project brings together researchers from Western Sydney University, Imperial College London, University of New South Wales, and practitioners from Metrologi, and Airbus Australia Pacific to develop specific nanotechnologies to be more durable in bonded joints. Secondly, Qinetiq Australia and RMIT were awarded $349,317 to develop a modelling framework that supports Multi-functional Shape Memory Alloy Tufted Composite Joints, or MuST technology. MuST increases systemlevel efficiency of materials and boasts a range of competitive advantages. In another project, University of New South Wales, London’s Imperial College, and Advanced Composite Structures Australia were awarded $349,946. The research project will power the use of advanced materials in armour—a pivotal component for military personnel in the defence sector. “Our aim is to give the men and women of both defence forces a competitive advantage, and this program will be a further important step in achieving that aim,” Minister Price said. A $330,500 grant was also awarded to RMIT University and BAE Systems to scope more effective metal-tocomposite hybrid joints. These joints will rely on developments in advanced materials to keep defence personnel safe. Finally, the University of Adelaide, France’s Research Institute of SaintLouis and the Materials Science Institute at Lancaster University received $209,510. Together, this project will investigate adhesives in ageing military platforms, and how vulnerable areas can be identified. Minster Price said these research partnerships were critical for securing a stronger defence industry for the future, and Australia’s position in the world. “Academic and industry partners are vitally important to both defence forces.” “Australia’s academics and small business sector have a wealth of talent and innovative expertise and the Next Generation Technologies Fund program is designed to draw out the best ideas to support our Defence capability,” Minister Price said.
A Disruptor in The Materials Space: AML3D Limited
Operating from a state-of-theart facility in Adelaide, AML3D is a disruptor in the metal part supply chain space. The company brings together world-class welding science, with robust automation processes to produce 3D materials.
AML3D’s patented Wire Additive Manufacturing (WAM®) technology supports greener, efficient, and smarter manufacturing processes. The patented WAM® technology provides a suite of benefits, including: • Products that meet near net shape • Robotic automation • Rapid fabrication • Layer on layer • Minimal stress • High deposition rates • Fully dense parts Unlike other technologies in the sector, WAM® is used to print metal parts in an open free-form fabrication environment. The process uses localised inert gas,which opens the window for a widevariety of possibilities for component manufacturing. AML3D recently announced an extension to the Stage 2 trials it has been conducting with Lightforce Australia for their next-generation ‘made-to-fit’ titanium body armour prototype trials. Results of the first phase of the Stage 2 testing scope identified additional opportunities across the ballistics range and testing plate parameters. Therefore, the initial testing scope has been expanded to accommodate this broader range. Lightforce is a developer and manufacturer of defence solutions, with operations across Australia and the United States. The Memorandum of Understanding between AML3D and Lightforce has resulted in AML3D’s WAM® being used to manufacture the early titanium body armour prototypes. Once the full range of detailed testing is completed and assessed, Lightforce will be focused on the commercialisation and business opportunities for the product range. WAM® has unique capabilities in that it is able to print bespoke, customised body armour using ‘unforgiving’ materials, such as titanium, with significantly lower emissions and less waste than traditional manufacturing techniques such as forging and casting. Andrew Sales (Managing Director, AML3D) said, “The global body armour market is massive and growing, so it is important that we cement a foothold in this market. It is a real credit to our team that their work on the earlystage prototypes of next- generation ‘made-to-fit’ titanium body armour has resulted in AML3D moving to the next stage of manufacturing and testing with Lightforce.” “We have the in-house capability and capacity to take on the commercialisation of ‘made-tofit’ titanium body armour and are confident that the quality of our prototypes in this next round of manufacturing and testing will deliver further successful results. This latest development follows a strong year for AML3D as we move from early-stage development of our business model to a company with sustainable and material revenue growth.”
AML3D’s WAM® is used to print metal parts in an open free-form fabrication environment.
DMTC Links Research with Practice for Increased Safety
Source: Sally Wood
Australia’s defence industry is underpinned by highly technical and advanced research that powers the next generation of armoured vehicles, ships, and technologies. As such, the University of Wollongong’s Defence Materials Technology Centre (DMTC) specialises in the weldability and performance of structural steel for the defence sector. DMTC analyses the strength of materials that are used in high-level defence and security projects and assesses any potential weldability issues. These issues consider whether fabrication is a viable option; what procedural constraints may exist; and better ways of thinking or manufacturing for the future. It is crucial that all defence components are made to measure, with little room for error. Weldability and process technology are linked. For example, high thermal intensity processes provide increased speed, a reduction in heat input, and lower distortion. However, these processes risk hydrogen assisted cold cracking in high strength steels. But research at DMTC and its partners is essential for managing these challenges in the sector and to bridge the gaps between research and practice. The DMTC has several key objectives: • Advancing the weldability and subsequent performance of high strength structural steels for ships • Advancing the weldability and performance of existing and alternative armour materials • Developing enhanced welding processes for improved productivity • Tailoring automation of air platforms • Tailoring automation and robotic welding for a range of platforms on land and in the sea • Improving welding repair and marine components In all, these priorities lead to improved productivity and sustainable manufacturing in Australia, which means that the sector is ready to grasp future opportunities in the defence sector.
Working Together for Increased Possibilities
The key to DMTC’s success is working collaboratively with a range of Australian industry partners. The centre brings together 16 research institutions, alongside government partners, including CSIRO; BAE Systems; Thales; and BlueScope. These institutions deliver enhanced defence and national security capabilities and strengthen Australia’s industrial capacity. Unlike other sectors, crosscollaboration in the defence sector is crucial for ensuring the safety and security of all Australians. DMTC is underpinned by high-quality research and technology adoption across the air, land, maritime, industry, health, and sensor systems.
HMAS Sirius (left) and United States Navy destroyer USS Stockdale conduct a replenishment at sea, while a helicopter from USS Carl Vinson, conducts a vertical stores transfer during Exercise Malabar, in the Indian Ocean.
HMAS Brisbane’s embarked MH-60R helicopter prepares to land on the flight deck, while transiting the Sea of Japan during a Regional Presence Deployment.
For example, a recent DMTC study analysed Australian carbon fibre capabilities, and their development for future defence projects. The study discovered new carbon fibre and composite manufacturing capabilities across Australia’s industrial and research sectors. “There is growing demand on defence projects for advanced materials, to take advantage of particular performance characteristics,” said Dr Mark Hodge, who is the Chief Executive Officer at DMTC. He explained that the project will provide a basis for DMTC to undertake future work in building Australia’s industrial capability and supply chain depth in this emerging area of the defence industry. “Composites can be attractive because they offer important performance characteristics including strength to weight ratio, ability to integrate functions, corrosion resistance and signature reduction,” Hodge said.
Air, Land and Maritime Capabilities at DMTC
At DMTC no stone is left unturned in regards to the safety of Australians, who remain at the forefront of all research and operations. In the sky, DMTC is capitalising on new technology horizons. The facility builds on the Federal Government’s Defence Strategic Update, which intends to build the Department of Defence’s capabilities in the air and in space. As such, DMTC is developing technologically advanced systems that will support intelligence gathering; surveillance; and reconnaissance. In practice, it will enhance communications and networking, and bring a new era of defence to life. This work capitalises on recent advances in materials science, such as the use of additive manufacturing technologies for air and space travel. On the ground, DMTC is working with the Australian Army to prepare for emerging threats. DMTC supports the ongoing development of better and smarter materials for Australia’s defence systems and platforms. These include reducing the payload of military systems on the ground; and providing greater mobility for personnel. For example, DMTC researchers recently developed a fuel cell auxiliary power unit. This concept could replace existing diesel generators on armoured vehicles, which are quite noisy. These hydrogen-powered fuel cells can run quietly for longer periods of time, and are an environmentally friendly alternative. The innovative solutions utilise research and development to deliver tailored solutions to DMTC’s high-level partners, and fill any gaps in the nation’s defence capabilities. Finally, DMTC forms a fundamental part of Australia’s ambitious naval agenda. DMTC works closely under Australia’s Naval Shipbuilding Plan, which seeks to position Australia as a leader in supply chains across the international shipbuilding and sustainment market. DMTC is a crucial piece of this puzzle, as the centre matches industrial innovation with science and technology. For example, DMTC has developed piezoelectric materials for sonar applications. This accumulates electric charges in some solid materials. It provides a depth to Australia’s naval capabilities through remote undersea surveillance.
Extra Funding to Fill DMTC’s Research Gaps
The centre recently received a new round of funding, from the Federal Government, to develop cutting-edge technologies. DMTC will harness existing textile technologies to develop a range of new protective suits that can withstand chemical, biological, radiological, and nuclear danger. Australia’s Minister for Defence Industry, the Hon. Melissa Price MP, explained that technology will be crucial for the Australian Defence Force and civilian applications. “This suit has the potential to reduce heat exhaustion and fatigue during very arduous activities”. DMTC has brought a diverse and multidisciplinary team together to work on this complex challenge. “Innovations that will protect our Australian Defence Force against chemical, biological, radiological and nuclear agents, demonstrate the ingenuity of Australian industry and the positive impact of partnering with Defence to build sovereign industry capability,” Minister Price said. The funding is part of the Federal Government’s Defence Innovation Hub, which invests in innovations generated by Australian industry, and research organisations alike. It intends to strengthen Australia’s sovereign defence industrial base as the nation prepares for a future with complex challenges and threats.
Bisalloy Steels’ Mega Defence Efforts Pay Off
Source: Sally Wood
Defence policy and equipment are highly complex in nature. There are several key components that must be considered, including geography, strategy, sustainability, and emerging threats.
Bisalloy Steels understands the importance of these concerns and provides a series of abrasion-resistant plates and equipment that is used for armour, structural, and wear-resistant steel applications. The company is Australia’s only manufacturer of high strength, quenched and tempered steel plates. So it’s no surprise that the name ‘BISALLOY’ has become synonymous for quenched and tempered performance steels in Australia.
"Bisalloy is the only quenched and tempered plate steel products manufacturer in Australia,” said Glenn Cooper, who is the company’s Chief Executive Officer and Managing Director. “This gives customers the ability to come to us to create one-off special blends, and tailored solutions for end user requirements,” he explained. At the company’s Australian production site, over 60,000 tonnes of steel is produced each year. Today, Bisalloy Steels employs 80 people across Australia, and over 150 internationally.
Protecting Australia’s Defence Force
The strength and reliability of Bisalloy armour steel has long been selected to protect Australia’s defence forces—an achievement of which Bisalloy Steels is justifiably proud. Bisalloy’s internationally recognised armour capability commenced with an order for hull plates for the local construction of two FFG 7 guided missile frigates. Bisalloy developed a local HY80 type steel in cooperation with (then) BHP Port Kembla and the Defence Science and Technology Organisation (DSTO) to a US specification that significantly outperformed the equivalent US manufactured steel plate. Australia’s four US-built FFG 7 frigates were subsequently retrofitted with the HY80 plate. Bisalloy went on to produce approximately 1,000 tonnes of steel for the FFG program. Thorough and detailed advance work resulted in Bisalloy becoming the preferred supplier for the Collins Class submarine program, at the end of the 1980s. Bisalloy supplied the Collins Class submarine program with more than 8,000 tonnes of hardened steel with excellent low-temperature impact properties — also developed with BHP and the DSTO.
Bisalloy successfully produced the BIS 812EMA plate; a weldable, microalloyed, high yield stress steel with excellent low temperature impact properties that had, until then, been an experimental Swedish product in its embryonic developmental stage. Specifically designed by Kockums Marine AB of Sweden for Australia's unique geographic and strategic circumstances, and built by the Australian Submarine Corporation in Adelaide, at the time, the boats were the most advanced diesel-electric submarines in the world.
The submarines originally had a predicted operational life of around 30 years, with the first ship, Collins, expected to be decommissioned around 2025. This timeline has somewhat changed, with the ships to remain operational until the new SEA 1000 Future Submarine project is delivered.
Since 1993, Bisalloy has produced over 3,500 tonnes of steel for the Bushmaster program. The Bushmaster was originally part of the Australian Army’s LAND 116 program, and was produced by Thales in Bendigo. It has been an extremely successful platform with over 1,100 Bushmaster variants produced, including exports to several countries.
More recently, Bisalloy has been working closely with Rheinmetall on the LAND 400 Phase 2 project. In June 2020, Bisalloy announced that the first of two high performance armour steel grades had passed stringent German Government certification after two years of research, development, and testing in collaboration with Rheinmetall Defence Australia. This qualifies the steel to be manufactured for Rheinmetall’s Australianbuilt BOXER 8×8 Combat Reconnaissance Vehicles (CRV). Bisalloy developed a new type of ‘O-grade’ armour steel in order to meet the protection levels required for the BOXER 8×8 CRV. Testing of even stronger ‘Z-grade’ armour steel will soon take place to meet the exacting protection levels required for each BOXER 8×8 CRV, and ensure the best protection for Australian soldiers.
Ongoing engagement with major defence prime contractors and manufacturers has been integral to Bisalloy’s defence business evolution. Bisalloy continues to work with companies such as South Korean based Hanwha Defense to achieve significant milestones for the Australian defence industry. As a result, all the Hanwha Redback vehicles, including their turrets (which are to be delivered for the upcoming Land 400 Phase 3 evaluation program)
will be built of Bisalloy steel. Bisalloy will also look to support Hanwha on the LAND 8116 program. Bisalloy has been a part of the process from the beginning, including detailed design, qualification, and testing, Bisalloy has been a part of the process.
Steel Hub Project Kicks Off with Bisalloy Steels
Despite Bisalloy Steels’ widespread international services, the company's heart remains in Australia. The company recently announced a collaborative new partnership with the University of Wollongong’s Steel Research Hub.
Under this agreement, PhD students will investigate and trial automated, or robotic wire arc additive manufacturing. This is a production process that is typically used to print or repair metal parts. Together, researchers and industry professionals will assess the additive manufacturing of welded materials, to fabricate welded hard-facing overlay on quenched and tempered steels. Hard-facing is a process that involves a single, or multiple layers of materials with unique properties. The materials are deposited on the base metal to increase its surface performance. As such, it typically leads to greater corrosion resistance. The technique deposits hard-facing consumable materials on surfaces, or in critical positions. The consumable materials are generally cheaper than the base material. This is a crucial research project for the industrial and defence sectors, where equipment is routinely exposed to extreme conditions, and the replacement of entire components is not a sustainable option. In addition, the sophisticated and automated nature of this process will grant a higher level of product quality consistency and assurance for clients. It will also lead to a reduction in labour, and an improved environment for operators. The University of Wollongong’s Steel Research Hub seeks to create a platform of teams which deliver innovative steel solutions and technologies. The $28 million centre connects nine universities with nine industry partners to accelerate Australia’s defence capabilities.
Bisalloy’s Defence Materials
A Bushmaster Protected Mobility Vehicle from the 2nd Combat Engineer Regiment, manufactured using Bisalloy Armour plate. © Commonwealth of Australia 2020.
Armour Steel
Offering quality that is second to none, Bisalloy Armour steel has become the first choice in defence applications, both here and abroad, and is specified for hulls in Armoured Personnel Carriers, Light Armoured Vehicles and the Bushmaster Infantry Mobility Vehicles. In addition to such traditional support for manufacturers of armoured vehicles, Bisalloy Steels is also increasingly supplying Bisalloy Armour steel to police, military forces, government and civilian applications worldwide for use in security vehicles, training facilities, security booths, splinter boxes, embassy ‘safe rooms’ and a myriad of other applications.
Protection Steel
Developed to complement the Bisalloy Armour steel range, the Bisalloy Protection steel range offers tested and certified, lighter weight plate products with superior ballistic performance to suit a wide range of applications for the protection of life, valuables and property. The Bisalloy Protection steel range runs the gamut of vital performance characteristics, including strength, toughness and shock loading resistance, and the ability to be readily formed, fabricated and welded. The Bisalloy Protection steel range also adds convenience to its list of attributes—it is a standardised product range that can be easily specified and ordered (even spot orders and small volumes) with short lead times. Source: steel Australia, Spring 2020
Titomic Breaks the Mould in the Defence Sector
Source: Sally Wood
Titomic provides next-generation defence and manufacturing services across Australia. Since 2014, the company has led the way in innovative solutions in the additive manufacturing space. But Titomic’s story begins much earlier. In 2007, Jeff Lang was invited by CSIRO to take part in the ‘Ore for More’ initiative, which sought to add value to Australia’s titanium mineral sands. Australia has the world’s largest deposits of titanium mineral sands, with over 300 million tonnes widely available. The initiative brought researchers, and industry professionals together to understand how larger volumes of titanium could be better utilised if they were manufactured at a higher speed or scale. As such, the project team developed a technique that supersonically placed metal particles onto a scaffold to develop metal coatings. This process created metal parts through a simple layer upon layer process of building particles. The findings were remarkable. The process provided a range of unique advantages for increased additive manufacturing possibilities. The breakthrough was such a success, that researchers patented and licensed the technology in partnership with CSIRO. It was dubbed the ‘Titomic Kinetic Fusion.’ As such, Titomic was born, with Jeff Lang as the company’s founder. Titomic’s focus was to commercialise the modern technology and develop other novel manufacturing capabilities. Today, the Titomic team still focuses on developing industrial-scale solutions using high-performing metals, such as titanium. The company understands the need to work collaboratively in the manufacturing sector. As such, Titomic works with colleagues — such as the defence and aerospace industry, and multiple government research bodies—to develop cutting-edge surface engineering and material science. Titomic embraces a strong research utilisation focus, which is backed by new technology. This approach has paved the way for new methods of manufacturing high-performance metal parts, and created several possibilities and nextgeneration manufacturing methods for defence-specific applications.
Titomic Kinetic Fusion for Defence Manufacturing
Titomic Kinetic Fusion has opened a new pathway of engineering possibilities for the defence and manufacturing sectors. The technology creates heterogeneous metal alloys that are not matched by other players in this space. The process consolidates manufacturing, fusing dissimilar metals, and creates heterogeneous metal alloys, which increase the performance of existing parts. Titomic Kinetic Fusion provides a suite of benefits to existing parts as it reduces weight, and increases strength and longevity. Through vigorous testing and research, Titomic has used high-performance alloys to deliver exceptional results. Similarly, Titomic’s Kinetic Fusion has allowed clients to manufacture composite metal armour, which is heat resistant, at an increased speed. By using metal alloys such as titanium, clients in the defence sector can create new armour materials by unlocking the possibilities through the patented Titomic Kinetic Fusion technology. Titomic can also manufacture heatresistant gun barrels for small arms or howitzers. This solves the complex problem associated with the manufacture of gun barrels, as gun barrels have traditionally been manufactured from a small range of alloys. The Titomic Kinetic Fusion innovation is expanding the scope of Australia’s barrel manufacturing and defence industries. The company believes that this technology can metallise plastics and composites, including carbon fibre, for lighter, stronger, and stiffer parts, across the defence and aerospace sectors. The technology creates large, and flawless parts, that can be manufactured up to four metres in diameter and three metres in length. It also allows a rapid manufacture, with minimal turnaround times. Together, these are essential pillars in the defence sector, where time is critical. Sustainable practices are also crucial to Titomic’s operations. The company has integrated renewable energy technologies and advanced manufacturing systems that are environmentally friendly. The international metal manufacturing industry generates around nine per cent of all carbon emissions. But Titomic Kinetic Fusion does not melt metal, and uses far less energy than traditional processes. As such, it leads to a 60 per cent overall reduction in carbon emissions. In addition, the company has a variety of waste minimisation schemes. Titomic Kinetic Fusion assembles parts that are very close to their final output, which has led to a company-wide reduction of waste by 80 per cent.
Titomic’s Ambitious Plans Are Out of This World
Titomic has ambitious plans to expand into the defence and space sectors, which are rapidly growing in Australia. Titomic was recently awarded a $2.325 million grant to manufacture and commercialise low carbon emission ‘green’ titanium space vehicle demonstrator parts. This grant will form part of a planned project expenditure of $4.65 million. It will power Titomic to use green titanium, materials blends, and other highperformance coatings, for genes shielding and greater protection in space. It will also capitalise on Titomic’s unique Kinetic Fusion additive manufacturing technology, to build and commercialise space vehicle parts with green titanium. The space sector is an emerging area of interest for the Federal Government, and Titomic’s funding reflects these interests.
