Rolls-Royce Backs Recycling Initiative for Tornado 2 Tempest Future Combat Aircraft

In a groundbreaking move towards sustainable aerospace manufacturing, Rolls-Royce has embarked on the Tornado 2 Tempest project. This initiative focuses on repurposing decommissioned Royal Air Force (RAF) Tornado components into powdered metal suitable for 3D printing, paving the way for eco-friendly production methods in the defense sector.

Project Overview

The Tornado 2 Tempest project is a collaborative effort involving Defence Equipment and Support’s (DE&S) Defence Recycling & Disposals Team (DRDT), the Ministry of Defence's Future Combat Air System (FCAS) team, Rolls-Royce, and Additive Manufacturing Solutions Limited (AMS). The primary goal is to assess the feasibility of transforming surplus military assets into valuable resources for future aerospace applications.

Process and Achievements

The project team identified retired Tornado components rich in valuable metals such as titanium, steel, and aluminum. Notably, jet engine compressor blades with high titanium content were selected for the recycling process. These components underwent thorough cleaning before being atomized into fine powders, known as feedstock, suitable for additive manufacturing.

Utilizing this recycled feedstock, the team successfully 3D-printed a nose cone and compressor blades for the Orpheus small engine concept. Subsequent operational tests confirmed that the 3D-printed nose cone met safety and functionality standards, demonstrating the viability of this recycling approach for aerospace applications.

Implications for Future Combat Aircraft

The success of the Tornado 2 Tempest project has significant implications for the development of future combat aircraft, particularly within the FCAS program. The Orpheus engine, serving as a testbed for next-generation technologies, benefits directly from components produced through this sustainable method. This aligns seamlessly with Rolls-Royce's Grow Combat strategy, emphasizing innovation and environmental responsibility.

Sustainability and Strategic Benefits

By repurposing surplus military assets, the project not only reduces waste but also enhances the UK's access to strategic metals, thereby decreasing reliance on external supply chains. This approach supports the Ministry of Defence's Circular Economics for Defence Concept Note, highlighting the potential for material reuse to improve supply chain efficiency and resilience.

Digital Integration and Future Prospects

A notable advancement within the project is the implementation of a Digital Product Passport. This tool records material provenance and lifecycle data, enhancing transparency in material allocation and helping to prevent counterfeit components from entering the supply chain.

The collaborative nature of the project, involving over 80 personnel including DRDT’s commercial graduates and Rolls-Royce apprentices, underscores a commitment to fostering innovation and developing sustainable solutions for future defense capabilities.

Industry Recognition

The Ministry of Defence has acknowledged the project's contributions by awarding Rolls-Royce a Chief of Defence Logistics and Support (CDLS) Commendation. This recognition underscores the initiative's role in advancing sustainability within defense logistics.

The Tornado 2 Tempest project exemplifies how innovative recycling methods can be harnessed to support the development of future combat aircraft. By transforming retired military components into valuable resources through advanced manufacturing techniques, Rolls-Royce and its partners are setting new standards for sustainability and efficiency in the aerospace industry.