→ ESA-RAL ADVANCED MANUFACTURING LABORATORY

WHAT IS ITS ROLE?

The ESA-RAL Advanced Manufacturing Laboratory provides expertise to investigate and optimise advanced materials and manufacturing processes in support of cutting-edge research and development. Support is provided on a range of topics including:

• Additive Layer Manufacturing (ALM)

• Joining Technologies

• Materials Processing

ecsat

WHAT SERVICES DOES IT OFFER?

Services on offer include:

• Powder characterisation

• Metrology

• Microstructural characterisation and heat treatment

• Mechanical testing and failure analysis

• Non-destructive residual stress measurement

• A gateway for accessing some of the extensive on-site testing facilities based on the Harwell campus

WHO ARE ITS CUSTOMERS?

Test services available to the European space community and industry

ALM optimised design of antenna mount

Rotary friction joining of Al tank to Ti tubing

Microstructure of additively manufactured 316L stainless steel

316L stainless steel (AM) after tensile testing

Micro-hardness testing

Scanning electron microscopy

Harwell Campus

→ ESA/RAL ADVANCED MANUFACTURING LABORATORY

HOW IS IT EQUIPPED?

The ESA/RAL Advanced Manufacturing Laboratory combines a range of state-of-the-art research equipment and techniques:

• Powder characterisation – apparent and tap density, flowability, powder size distribution and morphology

• Additive Layer manufacturing – EOS M290: parts built in stainless steel, Ti and Al alloys, Inconel, etc.

• Metrology – high accuracy dimensional measurements and surface texture analysis

• Mechanical testing – Tensile testing at elevated and cryogenic temperatures, hardness, Fractographic analysis

• Optical and scanning electron microscopy – microstructural observation of internal porosity, cracks, volumetric defects and grain morphology as well as compositional analysis (Energy Dispersive X-ray Spectroscopy)

• Metallographic sample preparation – sectioning, mounting, grinding, polishing, etching

• 3D X-ray tomography – building 3D models of materials and components from radiographic scanning techniques to identify internal defects

• Heat treatment – air, inert gas and vacuum furnaces up to 1600°C

• X-ray diffraction – crystal structure and phase analysis

• Residual stress measurements – neutron diffraction, XRD

• High-energy laser facilities – nondestructive testing and laser microscopy, spectroscopy

ecsat

HOW DO I FIND OUT MORE?

Please contact: tommaso.ghidini@esa.int or andrew.barnes@esa.int

Scanning electron microscope

Furnace

XRD

Powder characterisation

Sample preparation