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Aero engine, fabricated load-carrying structure, hot forming, and example of a component intended to be studied in the project
Photo: GKN Aerospace Sweden - RISE

Hot forming of lightweight bi-metallic parts with variable thickness

Lightweight design is increasingly in focus to the manufacturing industry. Fabrication imply that different alloys, thicknesses and material states can be combined in an optimal way to reach minimal weight, performance excellency and makes the production more effective, including hot forming and welding of bi-metallic components in superalloys.

Lightweight design is increasingly in focus to the manufacturing industry. Global environmental challenges, targets and legislations imply that lighter and more sustainable products are necessary to remain competitive. One strategic lightweight technology area for the aero engine industry focus on the unique possibilities that comes with fabrication, in which engine structures are built from sheet metal parts, forgings and castings that are welded together and heat treated to complete structures. The components also include reinforcements and interfaces created using AM. Fabrication imply that different alloys, thicknesses and material states can be combined in an optimal way to reach minimal weight, performance excellency and makes the production more effective.

Based on previous research work, this post-doc project aims at developing an innovative hot forming procedure for bi-metallic lightweight components with varying sheet thickness. The work is generic for different industry segments and involves virtual methods which includes coupled FE-analyses of the tailored blank, hot forming and welding to secure and shorten the tool and die development time. The project gathers competence from the aero engine industry in Sweden, acknowledged institute within manufacturing processes, FE-modelling and SME with experiences in sheet metal forming.

The project goals are:

  • To further develop and apply the generic methodology with coupled FE-analyses of the bi-metallic component with various thicknesses in superalloys. Simulation driven development of the innovative hot forming procedure that secures the resulting geometry and properties.
  • The SME manufactures and evaluates the tailored hot formed geometry desired by GKN.

 


Summary

Project name

LIGHTform

Status

Active

Region

Region Blekinge, Västra Götaland Region

RISE role in project

Participant, project manager

Project start

Duration

24 months

Total budget

4 450 000 SEK

Partner

RISE IVF AB, LaserTool i Blekinge AB, MagComp AB, Ryd-Verken AB

Funders

VINNOVA

Coordinators

Project members

Supports the UN sustainability goals

9. Industry, innovation and infrastructure
12. Responsible consumption and production
Lluis Perez Caro

Contact person

Lluis Perez Caro

Forskare

+46 10 228 46 68
lluis.perez.caro@ri.se

Read more about Lluis Perez