A unique supply chain for manufacturing of hot formed & welded aero engine sub-assemblies in nickel-base superalloys

Important results from the project

Within the project, a cold forming-hot forming and welding manufacturing process chain has been studied to evaluate the impact of replacing a cold formed part with a hot formed part in the existing production of a Vane-assembly in H282. The project demonstrates the technology and studies how hot forming may contribute to robust production with minimal material waste. Simulation studies and manufacturing by the project team show highly promising results. Geometry measurements of hot formed parts and the Vane-assembly show that it is possible to reach tolerances for production.

Expected long term effects

The project has generated a hot forming method where components are produced with minimal material waste and within desired tolerances. Joining of hot-formed parts with cold formed geometries show very promising results, process parameters used in existing production can also be applied to hot formed material. The supply chain has demonstrated the ability to undertake highly advanced manufacturing of aerodynamic aero engine components. The project has contributed to a granted LIGHTer-project and selected results are intended to be disseminated in scientific publications.

Approach and implementation

The project is based on simulation-driven development of experimental tools and processes around hot forming and joining of lightweight aero engine components. By combining the skills of specialized SMEs and researchers at RISE, challenging components have been manufactured through innovative manufacturing methods for hot forming and laser welding, which place high eligibility requirements on precision and technical excellence. Selected results is planned to be presented in aeronautical forums, submitted for publication in international scientific journals and to GKN.