Wings

Sustainable Aeronautical Innovation Through Recycling of Thermal Spray Residues

Introduction

In a context of economic and environmental recovery, the Walloon aeronautical sector is seeking to strengthen its resilience and sustainability. The WINGS project plays a key role in this transition by addressing one of the industry’s most overlooked challenges: the recycling of residual powders generated during the thermal spraying of abradable coatings in aircraft engine components.

These powders, typically discarded as waste, represent a valuable yet untapped resource. By applying its advanced materials characterization expertise, CRM Group is contributing to the development of innovative recycling pathways, reducing environmental impact while fostering a circular economy approach in high-performance manufacturing.

Objectives

The main objective of WINGS is to identify, validate, and scale up viable recycling routes for residual powder waste from the plasma spraying of the inner shroud of low-pressure compressor stators. These powders are composed of a mix of NiAl and AlSi/polyester, and their complex composition has historically made their recovery challenging.

Through in-depth characterization and pilot-scale validation, the project aims to transform this waste into new raw materials suitable for reuse in industrial applications. The project also supports broader goals of circularity, material efficiency, and resilience within the Walloon aerospace ecosystem.

Project Overview

From Waste to Value : Characterising Residual Spraying Powders

The project began with a thorough analysis of the powder residues using CRM Group’s full suite of material characterization tools, including:

X-Ray Fluorescence (XRF)
Inductively Coupled Plasma (ICP)
CHONS elemental analysis
Thermogravimetric Analysis coupled with FTIR (TGA-FTIR)
Scanning Electron Microscopy (SEM)

This multi-technique approach provided a deep understanding of the powder composition and morphology, enabling targeted valorisation strategies.

Two Promising Recycling Pathways

Based on the characterization results, two innovative recycling routes have been identified and are currently being validated at pilot scale:

Metal recovery through selective extraction of valuable constituents such as nickel and aluminium
Reintegration into production cycles by transforming the residual powders into functional fillers or coatings for non-aerospace applications

These solutions are being assessed for technical feasibility, economic viability, and environmental impact, with the ultimate goal of industrial implementation.

Towards Circularity in Aerospace Manufacturing

The WINGS project illustrates how targeted innovation can drive both sustainability and competitiveness in the aerospace industry. By transforming a complex waste stream into valuable resources, the project supports the Walloon region’s ambitions to lead in circular industrial practices and sustainable aerospace technologies.