Net Shape Manufacturing of Aeroengine Components
Xinhua WU,
The University of Birmingham
Abstract
Direct laser fabrication (DLF) and Net shape HIPping are two net shape
manufacturing technologies which are being studied in the IRC.
The direct laser fabrication technique can produce 3-D components from
their CAD files from metal powder and using a laser which moves
following the paths defined by the CAD file whilst powder is being
injected into the its focal point. Mechanical properties of the DLFed
Ti6Al4V will be reported and the correlation between the thermal
history and microstructure will be illustrated. Some demonstration
pieces will be shown.
Net Shape HIPping (Hot Isostatic Pressing) is a technology to
manufacture large components from powder to final shape component in
one step. This technology uses cheap mild steel as tooling/mould
material, which is filled with metal powder, followed by HIPping to
consolidate the powder. A net shape component is subsequently obtained
after removing of the tooling through machining/pickling. The geometry
of the tooling/mould is designed through sophisticated computer
modelling, taking into account the shrinkage during powder
consolidation, mild steel deformation etc. so that the final geometry
of the component is exactly that required after removing of the
tooling. The mechanical properties obtained using this technique are
similar to those in wrought components. Examples of the application of
this net shape HIPping technology in manufacturing aeroengine demo
components will be described.