Virtual process chain for superalloy sheet metal aero engine structures Validation and demonstrator

Purpose and goal

The project has successfully modelled and simulated a manufacturing chain of forming and welding of a double-curved component in alloy 718. The distribution of damage and the formation of cracks over the part can be predicted with high accuracy. Validation tests in cold and elevated temperatures were performed. The involved Swedish SMEs have increased their knowledge and knowhow to produce desired sheet-metal components in superalloys of commercial interest for GKN. All goals have been reached. Also the planned Lic. Degree was obtained.

Expected results and effects

The predicted shape deviations after forming and welding are in good agreement with the experimental tests. The damage and failure model accurately predicts the formation of cracks in the drawbeads. The damage distribution measured by acoustic emission showed similar results to the simulations. The industry could benefit from the presented FE methodology in order to create future manufacturing procedures for lightweight designs in which new advanced materials are combined in an optimal way.

Planned approach and implementation

The project combined research activities with experimental and validation tests of both forming and welding in alloy 718 in various 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. Hot forming simulations considering stress relaxation predict the desired parts within tolerance for production for GKN. New research challenges are identified.