Manufacturing of aircraft parts without machining

Summary

The project responses to the call for proposals under the Clean Sky Joint Undertaking to manufacture static engine components from INCO718 using Net Shape Hot Isostatic Pressing of powder (NSHIP). It involves 3 partners with complementary expertise in the areas required to undertake the work including powder characterization; NSHIP and modeling; low cost tooling, as well as microstructural and property assessment.

The NSHIP of powder has the potential to revolutionize the production of complex high performance aerospace parts enabling significant improved buy-to-fly ratios which give cost savings as well as environmental benefits.

To exploit this technology, significant challenges must be addressed including; difficulty in HIPping nickel super alloy powder, high cost of sacrificial tooling, diffused surface layer on components due to interaction with the tool material and finally the lack of credible performance information for IN718 parts produced using the NSHIP process.

The partners will use a rigorous and yet innovative approach to address these challenges in this 2 year collaborative project.

NESMONIC2

Objectives

CEIT-IK4's role

CEIT is the coordinator of the Project. Both Program Manager and Project Manager are CEIT researchers. As coordinator CEIT is responsible to prepare, administer, monitor and coordinate the activities of the project, maintain fluid communication between the partners, organize meetings and follow-up the activities scheduled in the project. In addition CEIT is also responsible for:

  • Establish the components requirements, geometrical specifications, material properties and components for validation

  • Assessment of powders, powder properties and HIP response

  • HIP processing trials in order to establish the limits of the processing window, based on the density, microstructure and mechanical properties of specimens

  • Assessment and compilation of NADCAP test results

  • Collaboration in the canister design for large and small demonstrator components

Partners

 

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