Rolls-Royce, the UK’s leading aerospace manufacturer, introduced the groundbreaking Tornado 2 Tempest program. As part of the Tornado 2 Tempest recycling initiative, it repurposes old Royal Air Force (RAF) Tornado components into valuable metal powder. This powder fuels Additive Manufacturing (AM) to create high-performance parts for Rolls-Royce’s Orpheus engine. As part of the UK’s Future Combat Air System (FCAS) project, the initiative aims to support the next-gen Tempest combat aircraft and promote both sustainability and aerospace innovation.
Transforming Surplus Military Assets into Aerospace Components
The Tornado 2 Tempest recycling program turns surplus Ministry of Defense (MOD) assets into feedstock for Additive Manufacturing. The program focuses on outdated or damaged Tornado parts, which contain titanium, aluminum, and steel. Rolls-Royce atomizes these materials into powder, then uses it to create new engine components.
A breakthrough in recycling titanium parts involved jet engine compressor blades from Tornado’s low-pressure air compressor. Rolls-Royce atomized these parts and 3D-printed new components for the Orpheus engine. After testing, the new parts met operational standards and proved safe for aerospace applications.
Advancing Sustainability and Self-Sufficiency in Aerospace
The Tornado 2 Tempest initiative reduces the need for raw materials, lessening environmental impact. It also addresses disruptions in global strategic metal supply chains. Supported by the UK Strategic Command’s Defence Support Organisation, the program aligns with the Ministry of Defense’s Circular Economics for Defence Concept. It further contributes to the sustainability goals of the FCAS program.
By recycling Tornado parts, Rolls-Royce cuts costs and lessens reliance on high-value metals. Additive Manufacturing produces components stronger than traditional forging methods, boosting military operations’ sustainability.
Enhancing Safety with Digital Product Passport
A Digital Product Passport tracks materials used in components, ensuring quality and safety. It prevents counterfeit materials and safeguards military-grade parts. This system reduces reliance on traditional supply chains while promoting aerospace sustainability.
Collaboration and Industry Recognition
Rolls-Royce, the MOD, Additive Manufacturing Solutions Limited (AMS), and other partners collaborated on the Tornado 2 Tempest initiative. Over 80 professionals worked together, combining expertise to implement sustainable solutions. The MOD’s Chief of Defence Logistics and Support (CDLS) awarded the team a Commendation for advancing defense capabilities.
The Tornado 2 Tempest recycling program sets a precedent for future aerospace technologies. It demonstrates how circular economy practices can provide secure, sustainable supplies of critical materials, paving the way for more resilient defense systems worldwide.
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