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Simulation of forming and welding processes for the manufacturing of bi-metallic aero-engine components in superalloys
Photo: GKN Aerospace Sweden - RISE

Validation of a fabrication process for bi-metallic 718/H282 component

In order to increase the competitiveness of the aerospace industry in Sweden, alternative manufacturing processes for static load carrying aero engine structures are desired. The concept of fabrication involves sheet metals, forgings and ingots assembled by welding, i.e. where two different alloys are welded into a bi-metallic engine structure

In order to increase the competitiveness of the aerospace industry in Sweden, alternative manufacturing processes for static load carrying aero engine structures are desired. New manufacturing methods and relations with sub-suppliers in Sweden are desired. The concept of fabrication involves sheet metals, forgings and ingots assembled by welding and heat treated. Fabrication implies with the possibility to increase design flexibility with the potential to combine different material states and alloys in an optimum way to reach Excellency in performance, efficiency and to reduce weight, i.e. fuel consumption (CO2). Also, fabrication increases the in-house level of processing which contributes to competitive product costs.

Shape distortions arise in the individual steps of the fabrication process chain. This imply a desire to perform coupled FE-analyses to predict springback, residual stress state and shape distortions with high accuracy in order to compensate forming tools for the accumulated shape deviation. Of special interest is the possibility to combine two different alloys in multiple material states by welding into bi-metallic engine structures.

Based on previous work in NFFP6 and by fundamental research on and development of processes for hot sheet metal forming, welding and heat treatment of Alloy 718 and H282, this continuation project shall result in optimal forming procedures based on virtual fabrication with coupled FE-analyses. The project also contribute to that a hand-picked SME with experience of sheet metal forming of advanced materials can further develop their product- and process development. The project gather competence from the aero engine industry in Sweden, acknowledged R&D within manufacturing processes, FE-modelling and SME with experience of forming. The aims of the project are:

  • Further development of a methodology for coupled FE-analyses of hot sheet metal forming, welding and heat treatments in superalloy bi-metallic components. Simulation driven development of hot forming procedures suitable for production of components in which resultant geometry and properties are secured. This continuation project involves the PhD student that obtained a licentiate degree in the previous NFFP6 project.
  • Development work where SME take necessary steps, to produce desired sheet metal components in superalloys for GKN. A bi-metallic prototype component is manufactured, assembled and evaluated in close collaboration with on-going projects at GKN.

(PhD thesis) Modelling aspects in forming and welding of nickel-base superalloys

Summary

Project name

NFFP 7

Status

Completed

Region

Region Blekinge, Västra Götaland Region

RISE role in project

Participant, project manager

Project start

Duration

26 months

Total budget

7 552 874 SEK

Partner

RISE IVF AB, Luleå University of Technology

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

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