Resource-efficient design of fatigue-resistant product by digital tools and innovative manufacturing

Important results from the project

The project explored the use of curve folding for turbine components to improve fatigue resistance. Design requirements were mapped through iterative meetings between companies. Machine limitations prevented use on selected components, so a simplified component was chosen for evaluation. A strategy for automated material data collection was developed, and the consortium was expanded with a steel producer and a vehicle manufacturer for the step 2 application.

Expected long term effects

The project show that curve folding has potential to enhance design possibility for fatigue-resistant products. The process can lead to fewer weld joints, which may reduce the risk of fatigue cracks. The strategy for automated material data collection shows great potential to enable more efficient databases and models through implementation and further development. It attracted interest from other industries and may contribute to the development of fatigue-resistant products in multiple sectors.

Approach and implementation

The project was overall carried out according to plan with relevant activities. Mapping and strategy work followed the timeline, but identifying a gas turbine component was hindered by unexpected machine limitations. This was addressed by evaluating a simplified component. Fatigue testing was performed to a limited extent. Collaboration worked well and the consortium was strengthened. External factors affected the project, but it largely developed as intended.