CDU's Project to Enhance Propulsion Parts
Charles Darwin University (CDU) is spearheading an innovative project to utilise high-speed 3D metal printing for the production of nickel aluminium bronze (NAB) parts, crucial for naval propulsion systems. This development addresses the manufacturing challenges faced in Australia, where traditional methods are no longer viable.
Funded by the Queensland Defence Sciences Alliance (QDSA), the project involves collaboration among CDU, James Cook University (JCU), the Australian Institute of Marine Science, and advanced manufacturing company SPEE3D. NAB is renowned for its strength, toughness, and corrosion resistance, making it ideal for marine applications such as propellers, pumps, and valves.
This project will utilise SPEE3D’s cold spray manufacturing technology to produce NAB parts and test their resilience in tropical seawater at the National Sea Simulator in Townsville. The testing phase aims to provide valuable insights into how these materials perform in unique Pacific tropical waters, where microbial communities are largely unstudied.
Kannnoorpatti Krishnan, CDU Research Professor, highlighted the project’s significance in providing reliable materials for the Australian Defence Force’s propulsion systems. “This reduces downtime, strengthens resilience in forward operating bases, and ensures continued operational effectiveness in contested maritime environments,” he said.
New Manufacturing Approach
The project not only addresses manufacturing challenges but also contributes to establishing a uniquely Australian supply chain. By combining SPEE3D’s deployable additive manufacturing platform with academic expertise, the project builds sovereign industry capability.
Steven Camilleri, CTO of SPEE3D and current PhD candidate at CDU, remarked on the importance of this technology in mitigating supply-chain risks. “With NAB being a supply-chain risk, our cold spray process is crucial to addressing this challenge,” he stated. SPEE3D is the only company in the world producing an NAB equivalent with this process.
JCU will play a critical role by incorporating rare earth elements into the alloy and assessing its corrosion resistance under various simulated seawater conditions. Field trials in tropical waters are expected to provide insights into material performance, enhancing the sustainability of naval systems.
QDSA Director Stuart Blackwell expressed pride in supporting this collaboration, highlighting its significance for marine applications across northern Australia. “The focus on innovative littoral capabilities is highly relevant, representing a step change in the future of logistics and sustainment,” Blackwell said.
This project not only aims to improve manufacturing efficiency but also secures a strategic advantage by advancing the knowledge of material behaviour in challenging environments. The collaboration promises to transform the production of NAB parts, ensuring they meet the rigorous demands of modern naval propulsion systems.
