Hot forming of lightweight tailored components for bi-metallic structures in superalloys

Important results from the project

The project has accomplished all proposed goals. The modelling and simulation of the hot forming procedure of a tailored and weight optimized sheet-metal component in alloy 718 was performed. Validation hot forming tests were successfully conducted. Further challenges remain to increase the forming temperature slightly to fine tune tolerances. All project participants can better produce and analyze hot-formed sheet-metal components with variable thickness of interest to the aerospace industry.

Expected long term effects

A comparison of the 3D scanned forming surfaces and the third plate shows promising results of the springback of the part, with a deviation of ±0.8 mm. These results will be validated after updating the FE simulations with the corresponding scanned forming surfaces and experimental temperature measurements. Inductive heating can effectively reach forming temperatures of 950 °C. The industry may benefit from this FE methodology to improve advanced manufacturing processes for lightweight designs.

Approach and implementation

The research activities and experimental validation hot forming tests were performed in alloy 718 according to the different work packages. The project activities have been successfully completed by combining advanced thermo-mechanical FE analyses together with the competences and equipment of the project partners. The use of proper process and thermo-mechanical material data, as well as accurate forming surfaces, in the FE simulations is key to the springback prediction of the component.