This brand new technology, based on Asymmetric incremental sheet forming (AISF), will transform the way many titanium sheet aeronautical components such as after pylon fairings, fan blades, exhaust ducts or air collectors are manufactured today. The innovative, cost-efficient and ecological forming technology to shape complex geometries in titanium that will contribute to strengthen the European aircraft industry competitiveness meeting society's needs.
Currently, aircraft industry uses complicated and cost intensive forming processes to shape complex Ti sheet components, such as deep drawing, hot forming, super plastic forming (SPF) and hydroforming. In some cases parts are even obtained by hand working. These techniques show severe drawbacks which include high costs, long industrialisation phases and high energy consumption rates.
On the contrary, main features of the innovative AISF technology to be developed will be an increased flexibility, cost reduction, minimised energy consumption and a speed up in the industrialisation phase.
The major impacts of the results obtained in the INMA project will be:
- Cost incurred by dedicated tooling will be reduced by 80%
- The component lead times will decrease by 90%
- Buy-to-fly ratios will be up to 20% lower
The INMA Consortium is integrated by 2 end-users, 1 equipment provider, 4 research organisations, 3 universities and the EASN association. Participation of industrial partners who will directly exploit the project results will guarantee the impact of the project.
PROJECT GOALS:The goals of the project are the following:
- Development of the AISF process for titanium through the generation of experimental data about adequate parameter windows, tool specifications and tool paths for cold, hot and large scale forming.
- Implement and validate numerical AISF process models that will provide reliable prediction of the forces, strains and shape deviations resulting from cold, lean heated and large scale forming.
- Characterize titanium formability limits, including the definition of specific and inexistent testing and evaluating procedures, as well as its post-forming metallurgical, mechanical and chemical properties under cold and hot AISF.
- Implement and validate an intelligent KB AISF process model that will serve to correct the forming tool path in order to compensate shape deviations appearing when no die is used.
- Develop heating procedures that will allow tackling hot AISF operations at minimum cost and energy consumption without compromising other relevant issues such as efficiency and reliability.
- Apply and validate the developed technology through the fabrication of aircraft and aeroengine realistic pilot demonstrators.
Characterize titanium under cold and hot AISF
2) The goal of this task is to characterize material post-forming properties of the grades of interest (i.e., Ti-40, Ti-15-3-3-3, and Ti-6Al-4V alloys) after the AISF. This includes static (tensile) tests supported by hardness measurements and metallographic analyses.
2) Description of not only mechanical properties of the processed samples of forming Ti-40, Ti-15-3-3-3, and Ti-6Al-4V alloys sheets, but also homogeneity of their microstructure.
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This innovation is the result of the project
Title: Innovative Manufacturing Of Complex Ti Sheet Aeronautical Components
Organisations and people involved in this eco-innovation.
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FUNDACION TECNALIA RESEARCH & INNOVATION
Field: Scientific research and development (Spain)
Role in project: Project Coordination
Contact person: Ms. PENALVA Mariluz
Phone: +34-943 105 115
AIRBUS OPERATIONS SAS
Contact person: Mr. PICOT Thierry
EADS DEUTSCHLAND GMBH
Contact person: Mr. LANG Werner
EASN TECHNOLOGY INNOVATION SERVICES BVBA
Contact person: Dr. PAPADOPOULOS Michael
INDUSTRIAS PUIGJANER S.A.
Contact person: Mr. MASAGUÉ Daniel
RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHEN
Contact person: Prof. SCHMACHTENBERG Ernst
THE UNIVERSITY OF LIVERPOOL
Contact person: Ms. SHAW Veronica
Contact person: Ms. PARKER Lucy
UNIVERSITY OF PATRAS
Contact person: Prof. LAMPEAS George
VYZKUMNY A ZKUSEBNI LETECKY USTAV A.S.
Contact person: Ms. MAKOVSKA Pavlina
WYTWORNIA SPRZETU KOMUNIKACYJNEGO PZL - RZESZOW SA
Contact person: Mr. HALIGOWSKI Robert