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FE simulation of forming and welding for the manufacture of sheet-metal components for aircraft engines in superalloys
Photo: GKN Aerospace Sweden - RISE

Virtual process chain for superalloy sheet-metal aero engine structure

In order to increase the competitiveness of the Swedish aerospace industry, alternative manufacturing processes for static load carrying aero engine structures are desired. The concept of fabrication involves sheet metals, forgings and small ingots assembled by welding. Flexible manufacturing may reduce weight, fuel consumption and product cost

In order to increase the competitiveness of the Swedish aerospace industry, alternative manufacturing processes for static load carrying aero engine structures are desired. The concept of fabrication involves sheet metals, forgings and small ingots assembled by welding. Fabrication implies the possibility to increase the in-house level of product refining, reduce weight, i.e. fuel consumption (CO2), and product cost. Shape distortions due to welding imply a desire to perform FE-predictions of springback, residual stress state and shape deviation with high accuracy in the different steps of the fabrication process in order to compensate forming tools for accumulated shape deviation. By fundamental research on and development of processes for cold and hot sheet metal forming of Alloy 718 and HAYNES® 282®, this project shall result in that a few hand-picked SME with different experiences within processing of sheet materials can further develop their processes for product and process development. The project gather competence from the Swedish aero engine industry, acknowledged R&D within forming processes, FE-modelling and SME with experience of forming. The aims of the project are:

  • Further development of effective methodologies for thermo-mechanical material characterisation for FE-analyses of cold and hot sheet metal forming in superalloys. Simulation driven development of forming processes suitable for production of components in which resultant geometry and properties are secured.
  • Development work where SME take necessary steps, to produce desired sheet metal components in superalloys for GKN. A prototype component are manufactured, assembled and evaluated in close collaboration with on-going research projects at GKN.

(Licentiate thesis) Modelling of forming and welding in alloy 718

Summary

Project name

NFFP 6

Status

Completed

Region

Region Blekinge, Västra Götaland Region

RISE role in project

Participant, project manager

Project start

Duration

54 months

Total budget

12 421 000 SEK

Partner

RISE IVF AB, AcousticAgree AB, ITE Fabriks 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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