Development of hybrid advanced manufacturing FAST-forge route for next generation aerospace components

开发下一代航空航天部件的混合先进制造 FAST-forge 路线

• 批准号: 2386023
• 金额: --
• 依托单位: University of Sheffield
• 依托单位国家: 英国
• 项目类别: Studentship
• 财政年份: 2019
• 资助国家: 英国
• 起止时间: 2019 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=studentship-2386023
• 关键词: Development; hybrid; advanced; manufacturing; FAST

Over recent years, researchers at The University of Sheffield have developed a hybrid solid-state processing route that converts titanium alloy powder into fully dense parts in two steps. Step 1 exploits the rapid sintering process - field-assisted sintering technology (FAST) to consolidate a range of titanium powder and particulates. FAST is different from conventional sintering methods as a current flows through the powder to achieve a Joule heating effect instead of using an external heat source. The team have demonstrated the consolidation of powders such as PREP, HDH, GA and machined swarf of a range of titanium alloy chemistries. The process produces densities comparable to hot isostatic pressing (HIP), however the advantages of FAST include consolidation times of up to 1 hour (as opposed to 4 hours in HIPing) and shaped preforms without the need for canning. Step 2; researchers at Sheffield have exploited the benefits of FAST to be an intermediate process for a subsequent one step forging stage to provide enhanced mechanical properties. FAST-forge is now being exploited for small to medium sized titanium alloy landing gear components.The benefits of FAST as a solid state diffusion bonding technique for powder have recently been realised (known as FAST-DB). Rolls-Royce titanium alloy and nickel superalloy powders have been successfully bonded using such a solid state technique. Potentially FAST-DB can be developed into a manufacturing route that can provide components with multi-alloy regions, for example to enhance creep and fatigue resistance in key subcomponent regions, ultimately increasing the life of aerospace components. The aim of this EngD is to exploit and further understand the characteristics of the FAST-DB and FAST-forge for aerospace alloy powders. The aim is to use ThermoCalc, DEFORM and COMSOL software to produce predictive models for industrial scale FAST derived components. An example of a key demonstrator component could be a compressor blade where different titanium alloys may be used for the aerofoil and dovetail. The project aligns with the large scale equipment earmarked for the Henry Royce Institute and objectives of the EPSRC Future Manufacturing Hub MAPP (Manufacture using Advanced Powder Processes). The objectives at the end of the project will be to transfer the knowledge to the High Value Catapult Centres for large scale exploitation into industry.Through the EngD you will be gain valuable and career defining experience in titanium and/or nickel superalloy metallurgy, process modelling, FAST, thermomechanical processing, mechanical testing, a range of characterisation techniques (electron microscopy, XRD), finite element modelling (DEFORM), physics-based modelling (COMSOL) and thermodynamic modelling (ThermoCalc). You will be expected to present results to Rolls-Royce on a weekly basis and engage with their materials and process modelling teams

近年来，谢菲尔德大学的研究人员开发了一条混合固态加工路线，将钛合金粉末转换为完全致密的部分，分为两个步骤。步骤1利用快速烧结过程 - 野外辅助技术（快速）以合并一系列钛粉末和颗粒。快速与常规烧结方法不同，因为电流流过粉末以达到焦耳加热效果，而不是使用外部热源。该团队已经证明了粉末，例如Prep，HDH，GA和一系列钛合金化学的加工Swarf等粉末的合并。该过程产生的密度与热等静力压力（髋关节）相当，但是快速的优势包括最多1小时的固结时间（相反，髋关节为4小时）和形状的预成型而无需罐头。步骤2;谢菲尔德的研究人员利用了FAST的好处，成为随后的一步锻造阶段的中间过程，以提供增强的机械性能。 Fast-Forge现在正在利用中小型钛合金起落架齿轮组件来利用Fast-Forge。快速作为粉末的固态扩散键合技术的好处最近已被实现（称为Fast-DB）。劳斯莱斯钛合金和镍超合金粉末已通过这种固态技术成功结合。潜在的快速DB可以发展为可以为组件提供多合金区域的制造路线，例如，以增强关键子组件区域中的蠕变和疲劳耐药性，最终增加了航空航天组件的寿命。该工程的目的是利用和进一步了解快速DB和Fast-Forge的航空合金粉末的特征。目的是使用Thermocalc，变形和COMSOL软件来生成工业规模快速衍生组件的预测模型。关键演示器组件的一个示例可能是压缩机刀片，其中可以将不同的钛合金用于驾驶和燕尾。该项目与专门为亨利·罗伊斯研究所（Henry Royce Institute）和EPSRC Future Manufacturing Hub Mapp的目标（使用高级粉末工艺制造）的目标保持一致。 The objectives at the end of the project will be to transfer the knowledge to the High Value Catapult Centres for large scale exploitation into industry.Through the EngD you will be gain valuable and career defining experience in titanium and/or nickel superalloy metallurgy, process modelling, FAST, thermomechanical processing, mechanical testing, a range of characterisation techniques (electron microscopy, XRD), finite element modelling (DEFORM), physics-based建模（COMSOL）和热力学建模（Thermocalc）。您将期望您每周向劳斯莱斯（Rolls-Royce）提出结果，并与他们的材料和过程建模团队互动