Virtual process chain for superalloy sheet metal aero engine structures

Published: 16 February 2015

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.

 

Contacts:

Project Manager: Eva-Lis Odenberger , LTU Senior Lecturer, Adjunct

Email: Eva-Lis.Odenberger@iuc-olofstrom.se

 

Project funding:

  • VINNOVA, NFFP6 for SME
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