Development of light-weight high-performance cast components

Purpose and goal

The goals of the project have been to produce lighter aerospace components than what is possible today and to develop simulation methods for thin casting and also to form a national supply chain of cast aerospace components. The goals set for the project have been achieved. In addition to this, TPC Components have been able to cast a full aerospace engine hub as a demonstrator.

Expected results and effects

The project results show that it is possible to cast complex structures with wall thickness down to 1.5 mm. Simulation methods have been developed that enables 25 % weight reduction. An important result is that the project has created possibilities for a national supply chain of cast components for the aerospace industry. The expectation is that suppliers of investment cast components, suppliers of materials and process knowledge as well as software suppliers in the future will form a strong and competitive innovation and supply chain in collaboration with the aerospace industry.

Planned approach and implementation

The work has been divided in two work packages, where the first has focused on method development. This work has to a large extent been performed by Swerea SWECAST and NovaCast. The second work package has focused on producing demonstrators to demonstrate the effects of the developed methods. This work has mainly been performed by the industrial partners under the lead of TPC Components in close collaboration with GKN Aerospace.