RESEARCH NEWS
WAAM for hydrogen storage tanks
Additive manufacturing experts from the University of Sheffield AMRC North West ( UK ) are exploring an innovative technique to produce hydrogen storage tanks for aerospace applications .
Dr . Evren Yasa , head of additive manufacturing ( AM ) for the AMRC , led a team of researchers on a project using Wire Arc Additive Manufacturing ( WAAM ). This production process is used to 3D-print metal parts with an electric arc to melt a metal wire , depositing layers of melted metal on top of each other , until the desired 3D shape is created .
Dr . Yasa said : “ This project was initiated to utilise our in-house WAAM capability to construct a demonstrator storage tank for liquid hydrogen using an aluminium alloy for use in the aerospace sector — and showcase the complete value chain for producing finished AM parts .”
Hydrogen is a highly sustainable energy carrier and is considered as a key to achieving climate neutrality in the EU by 2050 . However ,
Dr . Muhammad Shamir . challenges around how to store hydrogen limit its full potential , said Dr . Yasa .
“ The main challenges of storing hydrogen for use as a fuel source in aerospace , are the additional storage requirements , along with the complicated geometry needed for integral tanks as well as operation at cryogenic temperatures when it is stored in liquid form ,” she said . “ These challenges make AM technologies one of the promising manufacturing routes for hydrogen storage tank demands , which is also supported by the Cryogenic Hydrogen Fuel System and Storage Roadmap Report published by the UK ’ s Aerospace Technology Institute in 2022 .”
WAAM provides design freedom which resulted in the AMRC team making an array of more complex shapes , compared with the standard cylindrical / spherical shape — opening up the opportunity , particularly in aerospace , to potentially store hydrogen in more compact areas .
Dr . Yasa ’ s team wanted to explore the feasibility of using WAAM for metallic storage tanks by identifying the process parameters , as well as the deposition strategies , for good mechanical properties . Furthermore , the aim was to investigate and counteract the residual stresses occurring due to the high heat input generated during the WAAM process .
Dr . Muhammad Shamir , technical lead within the AM team at AMRC North West , explained how different types of heat sources can be employed in WAAM ( e . g . an electric arc or a plasma arc to melt the wire feedstock material ). He added : “ For our research , we focused on an electric arc process using a special technique to minimise heat input .” The seven-month project was funded through the UK High Value Manufacturing ( HVM ) Catapult , of which the AMRC is a member alongside six other national research centres . Dr . Yasa and her team now want to push the research to a second phase and are awaiting the result of a further funding bid to explore the effect of AM on the cryogenic mechanical properties , as well as hydrogen permeability to ensure that it is a feasible route for liquid hydrogen applications . n
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Paperless shop floor focus
AMRC Cymru is set to become the first facility in the University of Sheffield AMRC cluster in the UK to have a completely paperless shop floor . The innovative idea , which uses computer software and an interlinked touch screen kiosk to house all the necessary documents for a shop floor to function safely , was devised by AMRC Cymru ’ s senior manufacturing research engineer , Anmar Al-Qutayri .
Anmar ’ s avid interest in gaming and computers inspired him to devise the concept and he hopes to roll out the software to all AMRC shop floors , cementing the opportunity for the organisation to strengthen its longterm sustainability footprint .
He confirmed that the system is very easy to use and reiterated that users can store as many documents as needed , all in one place , and can be updated quickly without the need to use countless sheets of paper .
“ The stream deck , an interactive touch pad with tailored buttons that can be programmed to display images and documents , is an integral part of the system . Buttons on the stream deck can be
customised and take you to any videos or documents you use most frequently . It may be a small touch pad , but it ’ s simple and works very effectively ,” explained Anmar .
He highlighted that the impact of having this system in place helps to save paper , time , energy and money associated with having to manually create and use documents . It can also help to familiarise staff with machinery they ’ re not used to operating and can add a further element of interactivity to the shopfloor and enable engineers to keep up to date with safety documents as well as amend them at the touch of a button .
Andy Silcox , research director for AMRC Cymru , said the interactive systems gives engineers easier access to vital work documents , assessment check sheets and work instructions , rather than having to find the relevant documents in a paper format next to the machine . Matt Booth , workshop manager at AMRC Cymru , added that feedback on the system so far from staff and other companies visiting the site has been very positive .
Anmar Al-Qutayri .
Matt and Anmar began the task to set up the stream deck software system to work alongside a computer and touch screen , to be housed on a metal frame within close proximity of any machine on the shop floor at AMRC Cymru , based in Broughton , North Wales , in February 2023 . Four separate setups have now been successfully created and are ready to be implemented at the research facility , which is managed by the University of Sheffield and is a member of the High- Value Manufacturing ( HVM ) Catapult .
The full set up , which cost about £ 1,700 each , was funded from a £ 1.5m capital purchase grant secured through the Welsh Government , which is being used to help enhance the research facility ’ s capabilities and use on future collaborative research projects . n
ISMR November 2023 | ismr . net | 19