Development of a hybrid process chain for material-efficient production of aerospace componentsWednesday (26.09.2018) 11:30 - 11:45 S1/03 - 221 Part of:
In order to manufacture large aerospace components of aluminium and titanium alloys, usually a complex closed die-forging process is used. Forming is typically accomplished in several forging steps with soaking in between; several tools associated with high manufacturing costs are necessary to provide the required form filling and still the final part shape is obtained by machining, which leads to immense material waste during manufacturing. Additive Manufacturing (AM) could be used successfully in combination with forging in order to increase the efficiency of the process in terms of material and energy utilisation as well as costs. In this work different scenarios for hybrid manufacturing of a large aerospace component with ribbed structure made of aluminium and titanium alloys will be compared. Forging is used to obtain an optimum width-to height aspect ratio of the base part, thus assuring a microstructure with high degree of deformation. AM is applied to form the upper part of the ribs, where the area-bearing capacity dominates over the microstructure. Special attention is paid on the degree of material utilisation within the individual processes. Moreover, energy and cost efficiency of the hybrid processes will be analysed and discussed.