Rolls-Royce's Innovative Defense Initiative: Recycling Titanium for Future AM Jet Engine Components

Rolls-Royce Holdings plc, London, is making strides in sustainable defense manufacturing by repurposing titanium from obsolete fighter aircraft. This groundbreaking initiative focuses on recycling components like engine compressor blades from retired Tornado jets into titanium metal powders, which are then utilized for additive manufactured (AM) jet engine parts.

The Tornado 2 Tempest project involves extracting titanium from the U.K. stockpile of surplus Tornado aircraft. Surplus jet engine compressor blades from a low-pressure air compressor, were cleaned and atomized to produce metal powders for the Orpheus, a new small-engine concept. The recycled high strength lightweight titanium was utilized for components, such as nose cones and compressor blades.

Recently, an AM nose cone printed from recycled titanium alloys was successfully fitted to an Orpheus test engine, showcasing its performance and safety under testing conditions. The initiative also includes tracking material sourcing and lifecycle data, enhancing security against counterfeiting.