Objectives

Scientific

• Develop the world's first highly sensitive combined Ultrasonic and Eddy Current inspection system that will be capable of reliably and consistently detect all desirable defect types introduced during the titanium billet production process.

• Overcome the limitations of manual and current automated billet inspection systems by developing an autonomous scanner that will carry the range of sensors to comprehensively inspect a range of billet diameters and materials.

• Develop and significantly  improve NDT techniques and sensor systems, raising both their capability and reliability far beyond their current status, in order that defects specific to titanium billet such as 'Hard Alpha, High Density Inclusions or High Interstitial Defects originating from chemical segregation', are detected early in the manufacturing process.

• Increase accuracy and probability of detection, by reducing operator subjectivity. This increases inspection integrity and hence safety which in turn reduces the likelihood of catastrophic failure.

• Validate the developed techniques and instrumentation by means of a demonstration in a production environment.

• Conduct inspections faster by automating techniques and combining the inspections with other manufacturing operations. This will enhance safety and increase aircraft availability leading to reduced costs.

• Obtain an assessment of defect sensitivity in titanium billet diameters greater than 250mm to provide guidance for use in life management decisions as well as contributing to international standards.

Economic

• Achieve 20% savings on billet inspections for titanium manufacturers with a further 20% savings on inspections being realised by the aerospace industry (totalling € 21m per annum in Europe and € 75m worldwide) who will be able to extend inspection schedules or in some cases even eliminate subsequent component inspections.

• Increment the use of lightweight titanium (by developing novel inspection methods) for aircraft design and manufacture resulting in fuel savings/increased payload and reduced pollution. A 5% reduction aircraft mass by the use of Titanium will result in a savings of 30 million litres of fuel during the operational lifetime of a large modern airliner.

• Increase competitiveness of the EU NDT equipment manufacturers against fierce competition from USA and Japan.

• Reduce the cost of air travel due to fuel savings and/or higher payload capability resulting from the increased use of titanium in aircraft.

• Reduce rework levels for added value items by early identification of defects during the production process.

• Increase productivity by integrating the inspection and manufacturing operations, eliminating bespoke individual phases.

• Generate a minimum of € 180m in savings and sales, 4 years after project completion thus providing a total return on investment of 90:1.

Societal

• Reduce the number of accidents and loss of life resulting from Titanium component failures in aircraft and aircraft engines.

• Improve public confidence in air travel by providing more reliable inspection information and raising safety standards.

• Reduce operator stress levels by eliminating subjective data interpretation and monotonous tasks.

• Eliminate the necessity to manually lift heavy inspection equipment by using automation equipment instead. This will expand the opportunities available to female, disabled and ageing operators in this historically young male dominated engineering sector.

• Reduce environmental pollution by encouraging use of lightweight titanium in aircrafts. With fuel representing on average one half of the airlines' direct running cost, refusal to incorporate a 5% weight reduction, which has a marked reduction on fuel consumption, would impart a huge environmental and economic loss to society.