Innovation Exchange Challenge: Innovation in Functionally Graded Materials

Background

BAE Systems is a leading defence contractor with a presence in multiple countries worldwide. The company manufactures and maintains defence platforms for its UK and global customers. BAE Systems is aiming to improve platform safety, availability, capability, and reduce material waste, cost and schedule with the use of advanced functionally graded materials.

Traditionally, the current components are manufactured from wrought billets of Super Austenitic Stainless Steel and Low Carbon Steel that are welded together by tungsten inert gas welding.  The welding requires preparation, post-processing and machining to manufacture the final components resulting in significant material waste, cost and schedule delays. The use of welded dissimilar metals also affects the in-service functional performance of the components.

The Challenge

Propose technologies to manufacture a functionally graded material with continuously changing chemical composition comprising at least two or more materials, such as Super Austenitic Stainless Steel and Low Carbon Steel. The solution will help to address the material wastage, manufacturing complexity and performance issues of the current design where the materials are welded together and then machined. The main purpose of the challenge is to improve the functional performance of safety critical components, and realise materials and manufacturing efficiencies.

The prospective technology must be able to seamlessly manufacture a graded composition material billet comprising at least two or more metals/alloys, with mechanical properties matching or exceeding the constituent materials. Technologies that may be of interest include   cold metal spray, friction stir processing, laser powder directed energy deposition, hot isostatic pressing and other similar technologies and solutions.

Solutions should be TRL 6+ but newer technologies with TRL 3+ can be of interest. The technology shall be deployable for functional testing within 6 months of the competition, and commercially deployable within a year.

Eligibility

Entrants to this competition must be:

• Micro, small or medium-sized enterprise (SME)

Your project must:

• Have a grant funding request up to £25,000
• Last up to 3 months
• Carry out its project work in the UK
• Intend to exploit the results from or in the UK

Rewards & Market Opportunity

Successful applicants will be given an opportunity to pitch to BAE Systems. Selected solutions will be trialled with potential for further adoption if trials are successful.  The solution has the potential to be across business lines with 100s of components manufactured from the developed functionally graded material.

The benefits package for a successful applicant may also include:

• £25,000 seed funding
• Support from Innovate UK Business Connect.
• Support in the development of a prototype or pilot.
• Technical support.
• Invitation to attend or present at Innovate UK Business Connect events.
• A potential business collaboration.