Sustainable manufacturing of aero engine components in alloy 718

Important results from the project

The project aimed to evaluate the potential of the Quintus technology as a manufacturing method for aero engine parts with varying material thickness and thereby create possibilities to use sheet metal for manufacturing of parts with increased sustainability. A demonstrator geometry was proposed. A forming tool were designed, manufactured and analyzed through modeling and simulation where parameter studies indicated process robustness. A number of components have sucessfully been manufactured through collaboration to a 50% reduced energy consumption.

Expected long term effects

Within the project, tool geometries and process parameters have been established and a number of test parts in two different material thicknesses have been manufactures. The results indicate good agreement with simulation results and robust manufacturing. 3D scanning of test parts shows that the part geometry allows tolerances to be achieved after post-machining of the desired geometry. The project has successfully demonstrated the potential of the manufacturing method and its sustainability gains. Final processing has been sucessfully performed within production tolerances

Approach and implementation

The work is based on simulation-driven process development. By simulating a Quintus forming process, adjustments in process parameters and geometry changes have been carefully evaluated and optimized to accurately develop tools and the forming process that ensure a successful outcome. Experiences from previous research projects regarding material properties and material models have contributed to the results in the project. The project work has been successfully carried out within various project activities based on eligibility requirements and needs of GKN.