In this Q&A, John Sinks, division vice-president and business unit manager for AMETEK Specialty Metal Products (SMP), discusses the challenges and advancements in speciality metal materials that are driving this exciting era in aerospace and space exploration.

Aerospace is experiencing a renaissance, characterised by a surge in new aircraft designed to soar higher, further, and faster - while also reducing noise and emissions. Material science is at the forefront of this evolution. Advanced alloys and next-generation materials are making aircraft stronger, more efficient and cost-effective.

Q) What is the latest news regarding appointments, new equipment, facilities and purchases?

We have recently made several significant investments across our precision tubing operations. At our Fine Tubes facility based in Plymouth, we have increased our investment in non-destructive testing (NDT) capacity to enhance our quality assurance capabilities. Additionally, we have installed new 3D contactless scanner systems to accurately measure tube specifications, such as size and surface finish. These scanners provide real-time results, enabling us to achieve unprecedented precision.

At our Superior Tube Pennsylvania, US facility, we have expanded our tube reduction capacity for pilgering operations. Furthermore, we are continuing to integrate digital tools and automation in our manufacturing plants. This includes implementing production monitoring, statistical process control, and automated reporting systems to reduce our reliance on paper-based processes. These investments represent substantial enhancements to our tubing operations.

Q) Buy to fly ratios: is there a concern about scrapping material wastage and is the swarf bin at the back of the shopfloor increasingly becoming a dirty secret?

We are continuously striving to be leaner, more sustainable, and reduce scrap in our processes. This not only helps lower costs but also decreases our raw material consumption and reduces our carbon footprint. Our goal is to minimise raw material use by creating near-net shape products whenever possible.

Precision aerospace-grade tubes for engines and hydraulic systems

Additionally, we have collaborated with some of our suppliers to implement a closed-loop process for revert material. In this process, we segregate specific scrap and return it to the supplier for credit. The supplier treats and prepares this material for remelting, allowing it to be reintroduced into the industry as a new product.

Q) Is the growth of additive manufacturing a concern or are you already involved in the supply of AM powders?

Yes, we are actively involved in additive manufacturing. Our metals business comprises three distinct segments: tubing, strip products, and powders. Through our metal powder facility, we produce powders specifically designed for additive manufacturing applications.

Q) Space applications demand high-quality materials that deliver outstanding durability. What materials does AMETEK SMP manufacture for the space industry and which applications to they operate in?

Let’s start with the alloys that we really focus on – these are the speciality alloys, such as stainless steel, nickel, and different grades of titanium. Although they are more challenging to manufacture and meet high-end specifications, they are where it all starts for us in the space sector.

We are involved in several applications for propelling spacecraft, such as tubing for engines, instrumentation, and fuel lines. Our products are also used to manage heat, for example tubing for heat exchangers, and small strip materials and high-precision thin foils for heat dissipation. These are essential in electronics, whether it's for a rocket or for satellites.

Our high-purity nickel strip offers strong conductivity for advanced battery systems. Plus, it is lightweight which is important for space applications. Additionally, our powder and roll-bonded clad plate business supports the production of additive manufactured parts for magnetic shields, heat pipes, and thrusters, which must withstand high stress and temperatures.

Q) What are the primary factors that influence the selection of metal materials for space applications and how do these factors differ from conventional aerospace applications?

Historically, space missions involved long intervals between launches, often with single-use spacecraft. Today, however, the trend is toward reusable rockets that can be launched more frequently and reused. This shift necessitates materials that maintain their integrity and performance over multiple launches and missions. Having materials that can withstand the higher temperatures, higher pressures and extreme conditions over multiple projects and launches is vital.

Q) Can you describe the key challenges in ensuring the durability and reliability of metal materials used in space environments, considering factors such as extreme temperatures, radiation exposure and vacuum conditions?

It all starts with securing high-quality alloys and materials from reliable suppliers. The right materials are essential to withstand the harsh conditions of space. Next, our new product development teams undertake rigorous engineering and testing. We specialise in pushing the boundaries when it comes to manufacturing products that meet key parameters to endure the extreme space environment.

Highly conductive nickel strip for aerospace battery packs

Meeting customer specifications is a top priority. We work closely with OEMs who develop their own niche alloys. We test these materials to ensure they meet necessary performance criteria. In some cases, we refine existing alloys and specifications to enhance their performance.

Q) What advancements in material science are necessary to support the trend towards miniaturisation in satellite technology? How do these advancements address the challenges of designing smaller, lighter satellites capable of maintaining higher performance and longevity?

We have seen a significant trend towards miniaturisation not only in the space industry but also in other sectors such as electronics. Leveraging our expertise from these fields, we apply similar advancements to our space projects.

For instance, our thermal management products, used for effective heat transfer in electronics, are now being adapted for use in satellites. As satellite electronic components become increasingly compact, these innovative materials help dissipate heat efficiently while supporting the miniaturisation process.

Everything is getting smaller. Another example is our pure nickel strip for space battery systems. The higher conductivity of our battery tab material enables designers to continue miniaturising the size and weight of battery packs without sacrificing power handling capabilities.

Q) What do you feel are the most important assets of a company: a defined strategy, its people, its experience, its use of technology, its locations or a combination of all these points?

For AMETEK SMP, the most important assets are a combination of all these factors. However, our people make the most significant difference. The way we recruit, onboard, develop, and retain key talent is crucial to our success. We have developed an industry-leading culture that prioritises safety above all else.

Q) What makes AMETEK SMP different from the competition? Why should a customer use you over your nearest rival?

Our customer surveys, most recently completed in the fourth quarter of 2023, confirm that AMETEK SMP is consistently regarded as the most reliable supplier. That, I would say, is what makes us stand out. This reputation is built on our ability to deliver high-quality, reliable service across all segments, particularly for critical applications with the most challenging specifications.

Metal additive powders engineered for space components

Additionally, the structure of AMETEK SMP provides a significant advantage. As part of a large organisation, we have access to extensive resources. Our decentralised business units allow us to remain nimble and responsive to our customers' needs. This balance of scale and agility is a key differentiator.

Q) Would you say that your long-standing partnerships have brought huge benefits, particularly as trusted relationships can lead to a better way forward for all?

Absolutely. Our longstanding relationships with customers have naturally led to increased business opportunities. If you're a reliable supplier, your customers will come back to you when they need new materials, or if they're expanding into new applications.

It’s the same with our suppliers. Our trusted relationships have allowed us to expedite materials that are most critical to our customers, despite challenging global events and issues with logistics. We have effective stocking programmes in place to help us better serve them. There's no doubt that our strong track record with long-term suppliers has been instrumental in maintaining a steady supply chain.

Q) Finally, a crystal ball question: what next and what will be the challenges you face in the future?

Aerospace is experiencing a renaissance right now, shown by proliferation of new vehicles reaching space and flying higher, faster, and more efficiently than ever before. This surge in innovation brings with it increasingly demanding requirements for the materials used in satellites and rockets, which is an excellent fit for our business. We thrive on fulfilling customised orders, whether it's engineering a new alloy or developing alternative forms of tubes, strip, or powders to meet unique specifications.

One enduring challenge we face is recruiting the right talent. Finding skilled operators to manufacture our products, and qualified engineers to develop and turn them into business leaders is crucial.

Additionally, we have a robust strategy for new product development. We are investing heavily in our manufacturing capabilities, incorporating more automation and digitalisation to stay ahead. Overall, we are optimistic about the future of AMETEK SMP and its people, particularly within the aerospace and space markets.

AMETEK Specialty Metal Products will be exhibiting at the Farnborough Airshow on stand 41314.

www.ametekmetals.com