The use of the sprayforming technologies has extended in several automotive applications, with a range of components manufactured from different alloys like tool steels, aluminium, bronze. Recent results of the European funded research project OPTISPRAY Nr. GRD1-2001-40168 are presented here on the application of this process to the manufacture of Aeroengine Components in IN718 and U720 alloys. These components are mainly Low Pressure Turbine casings (and likely others of similar geometries), where the much shorter proposed manufacturing route would mean a significant cost reduction. The process key parameters ruling final results have been investigated and optimized, with the aid of modeling, to finally obtain a product with the appropriate quality to be used in the intended aerospace application. A different previous paper focuses on the spraying process parameters and post-processing routes optimization, performing the metallurgical study of the produced material. Herein, the products coming from these different routes have been assessed through mechanical tests, and the results are presented. All considered facts of technical suitability and economy of the proposed manufacturing route indicate the interest of availability of the process for aeroengine manufacturers. Sprayformed material post-processed by different routes meets the usual specification requirements placed on forged material, showing in many cases wide margins over those requirements. The residual porosity that remains on the as-sprayed material is healed by the post-processing operations, such as HIP and forging. No detrimental effect from that previous porosity could the observed on the tensile properties of the materials. When the as-sprayed material is forged, this process is quite enough to get rid of the remaining porosity. Application of HIP before forging shows little improvement on mechanical properties (mainly in ductility), though it may be required for manufacturing issues. Given that the mechanical properties requirements of parts produced by the sprayforming method are met, this supports the interest of using the process as a cost reduction opportunity, replacing the more complex routes of forgings. Other kind of tests, like LCF, Charpy, creep and stress rupture, will be performed on the produced material. All these will allow completing the study of the produced material and giving further comparisons of the three different post-processing routes. Besides, two different component prototypes have been produced, following the routes of only HIP (simplest) and the complete HIP + ring rolling one (most complex). These will be assessed in more detail, including more mechanical tests and other manufacturing operations, such as machining, to further assess feasibility of producing components from this kind of material. For the simplest one, the alloy 720 was chosen, and a part was due to be produced by Turbomeca. For the most complex route, IN 718 alloy was chosen. Here a component was produced also from the sprayed rings, but now including the different operations or manufacturing steps that were considered in the study (as HIP) or that were necessary to achieve the final geometry (ring rolling).


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    Titel :

    Sprayforming optimisation of superalloy aeroengine components


    Weitere Titelangaben:

    Optimierung des Sprühkompaktierens einer Superlegierung für Flugzeugantriebsbauteile


    Beteiligte:


    Erscheinungsdatum :

    2005


    Format / Umfang :

    13 Seiten, 17 Bilder, 9 Quellen


    Medientyp :

    Aufsatz (Konferenz)


    Format :

    Print


    Sprache :

    Englisch




    Rapid Tooling by Sprayforming

    Roche, A. / Jordan, R. M. | British Library Conference Proceedings | 1995



    Metal Injection Moulding for Manufacturing Aeroengine Components

    Kraus, M. / European Powder Metallurgy Association | British Library Conference Proceedings | 2001