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FP7

CESAME Sintesi della relazione

Project ID: 620103
Finanziato nell'ambito di: FP7-JTI
Paese: France

Final Report Summary - CESAME (Cost Effective Superalloy for Advanced Modern Engine)

Executive Summary:
The requirements in term of noise and fuel consumption reduction lead to the developments of new engine technologies. Within this framework, Clean Sky ambition is to develop and promote all the technologies which can participate to enhance environmental performance of modern aircrafts. Within that context, the metallurgical industry faces to new challenges due to the development of technologies for sustainable and green engines.
Aubert&Duval has been producing superalloys since the 60s. Since then, Aubert&Duval has become a major producer of engine disks, for all jet engine manufacturers around the world. Aware of these evolutions, Aubert&Duval has worked to propose a new innovative superalloy avoiding isothermal process, named AD730™, able to answer to the evolutions of the market toward Green and Sustainable Engines. It has to be noticed that Aubert&Duval is the only company in Europe enough integrated to be able to design, elaborate, transform and heat treat a new superalloy such as AD730™. This new superalloy was designed to be capable of mechanical characteristics similar to U720Li, a well-known superalloy capable of working to high temperatures (up to 700°C), contrary to DA718 which can be limited for first rotor stages applications in the LPT of new engines. Actually, these new engines will work at higher temperatures compared to classical engines. The breakout brought by AD730™ comes mainly from its unique cost properties combination. Moreover, this cast and wrought alloy can be forged under a classical hydraulic press, and does not require to be forged in an isothermal press. Aubert&Duval aims through that project to create a new 100%European made processing route for high temperature engine disks allowing cost and energy savings, compared to the classical U720Li processing route.

The objective of CESAME project is to demonstrate the industrial capabilities (similar or higher properties and cost reduction process) of AD730™, new superalloy developed by Aubert&Duval, to substitute U720Li for disk applications in aero-engine. To show that AD730TM alloy is a serious cost-effective solution to substitute U720Li alloy in the future gas turbine engines, several objectives should be achievable within the CESAME project and are summarized below:
- To demonstrate the capability of AD730TM alloy to be manufactured at minimum cost compared to U720Li manufacturing process
- To demonstrate the final properties of the AD730TM parts after close die forging and heat treatment are at least similar to or higher than those of U720Li parts

CESAME project has shown that the new European superalloy, AD730TM, is a suitable alternative to replace the classical U720Li alloy regards manufacturing process cost and properties. Mechanical properties and ultrasonic inspectability obtained on AD730TM parts were found similar and even higher than those obtained on U720Li parts. During the project, technical and cost saving optimizations of AD730TM process were performed. It was so demonstrated that the use of larger ingots up to 25’’ diameter is possible with AD730TM alloy without any detrimental effect on mechanical properties. This new manufacturing route is a step forward to reduce the AD730TM manufacturing cost regards U720Li. CESAME project achieves to demonstrate that the new European superalloy, AD730TM, responds to the requirements of the aeronautic engine market in term of energy and cost saving.
To make full use of the results of the project, Aubert&Duval is eager to disseminate the results from this project as widely as possible and to maximize the commercial impact of the results through a strategic exploitation plan. The CESAME project gives a strong comparison of AD730 properties versus U720Li properties which will be published on scientific publications in order to share with the scientific community the knowledge learnt. Presentation of paper at Superalloys 2016 conference is so planned.

Project Context and Objectives:
Project context
The requirements in term of noise and fuel consumption reduction lead to the developments of new engine technologies. Within this framework, Clean Sky ambition is to develop and promote all the technologies which can participate to enhance environmental performance of modern aircrafts. Within that context, the metallurgical industry faces to new challenges due to the development of technologies for sustainable and green engines.
Aubert&Duval has been producing superalloys since the 60s. Since then, Aubert&Duval has become a major producer of engine disks, for all jet engine manufacturers around the world. Aware of these evolutions, Aubert&Duval has worked to propose a new innovative superalloy avoiding isothermal process, named AD730™, able to answer to the evolutions of the market toward Green and Sustainable Engines. It has to be noticed that Aubert&Duval is the only company in Europe enough integrated to be able to design, elaborate, transform and heat treat a new superalloy such as AD730™. This new superalloy was designed to be capable of mechanical characteristics similar to U720Li, a well-known superalloy capable of working to high temperatures (up to 700°C), contrary to DA718 which can be limited for first rotor stages applications in the LPT of new engines. Actually, these new engines will work at higher temperatures compared to classical engines. The breakout brought by AD730™ comes mainly from its unique cost properties combination. Moreover, this cast and wrought alloy can be forged under a classical hydraulic press, and does not require to be forged in an isothermal press. Aubert&Duval aims through that project to create a new 100% European made processing route for high temperature engine disks allowing cost and energy savings, compared to the classical U720Li processing route.

Project description (objectives)
The main objective of the CESAME project is to demonstrate the industrial capabilities (similar or higher properties and cost reduction process) of AD730™, new superalloy developed by Aubert&Duval, to substitute U720Li for disk applications in aero-engine. To show that AD730TM alloy is a serious cost-effective solution to substitute U720Li alloy in the future gas turbine engines, several objectives have been defined for CESAME project:
- To demonstrate the capability of AD730TM alloy to be manufactured at minimum cost compared to U720Li manufacturing process
o To evaluate the capability of AD730TM alloy to be melted at minimum cost for production of ingot
o To evaluate the capability of AD730TM alloy to be converted at minimum cost for production of 10’’ billet
o To evaluate the capability of AD730TM alloy to be forged and to be heat treated in an industrial environment
- To demonstrate the final properties of the AD730TM parts after close die forging and heat treatment are at least similar to or higher than those of U720Li parts
o To evaluate the final properties of the parts after close die forging and heat treatment

Project Results:
Final project results
In this paragraph information is provided on the Work Packages (WP) objectives, major achievements and deviations. In this way the final project results are provided.

WP1 Management
Objectives:
The main objective of WP1 is to establish and execute a management and administrative system for smooth project execution. This involves system for overall project planning and co-ordination and proper progress reporting. The role of the project coordinator includes the following main objectives:
• Management of the project and the coordination of the 5 WPs.
• Ensure the work progress is in line with the initial plan
• Communication and reporting to the Topic Manager and to the JU
Achievements:
• Coordination of the team dedicated to the project (internal telecom meetings and physical meetings to follow the work progree)
• Reporting to the Topic Manager with monthly telecom meetings and physical meetings each six months
• Assuring the submission of deliverables and periodic reporting
• Preparing the financial declaration and reporting
• Have email contact with project and/or financial officer when needed
Comments/deviations:
• The first Periodic Report was delayed because the Audit Report consumed more time than expected and then the procedure required by the European Commission was not completely followed so the Audit had to be completed before submission.
• The project planning was adapted in order to take into account the modification made in WP2.
• From the management point of view it has always been tried to keep the delays as limited as possible. We have also always been in close contact with the Topic Manager to discuss the best approach forward.

WP2 Development of a cost optimized melting process
Objectives:
The objective of WP2 is to evaluate the capability of AD730TM to be melted at minimum cost for ingot production:
- Optimizing the melting process for future process up scaling
- Producing ingot with a cost optimized melting route (ingot will be then converted on WP3)
Achievements:
• Two optimized melting routes were defined
• Two AD730TM ingots with different size diameter (20’’ and 25’’) were successfully melted
Comments/deviations:
Two ingots instead of one were made in order to secure the project and to obtain safe results for a reliable cost comparison with the two sizes of ingots. Because of the additional ingot and an alea with ESR mold of the 25’’ ingot, the time-schedule for this WP was delayed of 3 months. New deadines were agreed with the Topic Manager and the ESR mold was mended in the shortest possible delay.

WP3 Development of a cost optimized conversion process
Objectives:
The objective of WP3 is to evaluate the capability of AD730TM to be converted at minimum cost for 10’’ billet production:
- Optimizing the conversion process for future process up scaling
- Producing 10’’ billet with cost optimized melting route (billet will be used for forged parts on WP4)
Achievements:
• Two optimized conversion routes were defined
• Two AD730TM billets from ingots with different sizes (20’’ and 25’’) were converted
• AD730TM and U720Li billets were characterized and results were compared
Comments/deviations:
As explained in WP2, a new time-schedule was built in order to take into account the delay on WP2, so, concerning WP3 it meant a deviation of 4 months from the initial planning. In addition of that, the task T3.3 was two months longer than planned because of busy production activity at that time. New deadline for the deliverable D3.2 was agreed with the Topic Manager and to reduce the WP3 delay impact on WP4, it was decided to perform the tasks T3.3 and T4.3 in parallel.

WP4 Development of die-forging process and heat-treatment
Objectives:
The objective of WP4 is to evaluate the capability of AD730TM to be forged and heat-treated in an industrial environment.
- Determine optimized forging process for AD730TM
- Producing LPT disks (up to 10) which will be characterized in WP5
Achievements:
• Design of close-die forging process through modelling
• Design and fabrication of the dies
• Close-die forging and heat treatment of 6 AD730TM parts from Heat 1, 2 U720Li parts and 5 AD730TM parts from Heat 2.
Comments/deviations:
Due to a busy production activity, close-die forging of AD730TM parts (Heat 2) was delayed of two months. However, major efforts were made to reduce this delay (using subcontracting instead of internal work and to reduce the impact on the following WP5: UT inspections were done in priority and time allowed for mechanical tests were optimized as far as possible in order to respect the global time limit of the project (end of September 2015)

WP5 Evaluation of microstructures, mechanical properties and internal flaws
Objectives:
The objective of WP5 is to evaluate final properties of AD730TM and U720Li parts after close-die forging and heat-treatment:
• To perform ultrasonic testing (UT) on all parts
• To observe and compare microstructures
• To perform mechanical tests and to compare mechanical properties of AD730TM parts from 20’’ ingot, AD730TM parts from 25’’ ingots and U720Li part
Achievements:
• Definition of cut-up plan
• Definition of the UT procedure and validation of the Topic Manager
• Performing UT inspection on 8 AD730TM parts and 2 U720Li parts
• Performing cut-up on 4 AD730TM parts and 1 U720Li part
• A reliable comparison on AD730TM and U720Li properties was done
Comments/deviations:
Major efforts were made to reduce the WP4 delay impact on WP5: UT inspections were done in priority and time allowed for mechanical tests were optimized as far as possible in order to respect the global time limit of the project (end of September 2015) so WP5 delay was limited at one month.

WP6 Analysis and substantiation of total billet production cost
Objectives:
The objective of WP6 is to analysis the reduction cost of AD730TM process which can be possible and to compare AD730TM process with U720Li process. This work package dealt with the exploitation and dissemination of whole project results.
Achievements:
• For each milestone corresponding at each step of the process (melting, conversion and close-die forging) and for two ingot sizes, an evaluation of the process cost for AD730TM was made and compared to U720Li process cost.
• A reliable demonstration was so made to show the capability of AD730TM alloy to be manufactured at lower cost compared to U720Li.
• Participation at Superalloys2016 conference through an oral presentation in order to disseminate and promote the valuable results obtained with CESAME.
Comments/deviations:
One month delay regarding the initial time-schedule for WP6 due to the accumulative minor delays taken from previous work package. New deadline for deliverable D6.1 was agreed with the TopiC Manager.

Overall conclusions

All the objectives defined at the beginning of CESAME project (given in paragraph 2.2) were achieved with respect to the initial global time-schedule of 24 months. Two AD730TM process routes (from two different ingot sizes) were studied with a combined technical and cost saving approach. The first AD730TM process route is based on the conventional ingot size used with U720Li (20’’ diameter) whereas the second AD730TM process route is based on a larger ingot (25’’ diameter) which is an innovative approach for this kind of superalloys as AD730TM. Forged parts with same design were produced from AD730TM and U720Li materials and fully characterized; it means that UT permeability, microstructure and mechanical properties were checked and compared. A reliable comparison between AD730TM and U720Li alloys was so performed within CESAME project. It was shown that AD730TM characteristics are at least comparable to U720Li alloy and, for some conditions, higher properties were found. Moreover, it was demonstrated that AD730TM properties are accompanied with lower manufacturing costs regards U720Li process costs. It was also demonstrated that the second AD730TM process route using larger ingot up to 25’’ studied during CESAME project is really promising and is a step forward in cost reduction of AD730TM process compared to U720Li.

CESAME project management
Meetings
In the past two years many meetings took place. The table below provides a complete overview of all meetings that took place during the full project period.
Date Venue Purpose Participants
07/10/2013 Les Ancizes Internal kick-off meeting on Les Ancizes Plant AD
11/10/2013 Pamiers Internal kick-off meeting on Pamiers Plant AD
24/10/2013 Munich Kick-off meeting AD + Topic Manager
Each month Telcom Progress meeting AD+Topic Manager
Regular Telcom, email, meetings Progress meeting with WP leaders AD
05/11/2013 Pamiers Technical meeting with WP4 team AD
15/11/2013 Les Ancizes Technical meeting with WP leader (WP2+WP3) AD
28/11/2013 Telcom Technical meeting with WP4 team AD
29/11/2013 Les Ancizes Technical meeting with WP2 team AD
2014
07/01/2014 Telcom Technical meeting with WP4 team AD
24/01/2014 Les Ancizes Technical meeting with WP2 team AD
27/01/2014 Les Ancizes Technical meeting with WP3 team AD
04/02/2014 Telcom Technical meeting with WP4 team AD
27/02/2014 Les Ancizes Technical meeting with WP3 team AD
25/03/2014 Pamiers Technical meeting with WP leaders AD
08/04/2014 Telcom Validation of the close-die forging procedure AD+Topic Manager
16/04/2014 Les Ancizes Technical meeting with WP3 team AD
07/05/2014 Telcom Preparation of review meeting with the project team AD
22/05/2014 Les Ancizes Review meeting AD+Topic Manager
04/07/2014 Les Ancizes Technical meeting with WP3 team AD
17/07/2014 Pamiers Technical meeting with WP4 team AD
23/10/2014 Clermont-Ferrand Presentation of 1st year results for AD management AD
29-30/10/2014 Munich Review meeting AD+Topic Manager
02/12/2014 Pamiers Validation of UT procedure AD+ Topic Manager
2015
22/01/2015 Telcom Progress meeting with WP leaders AD
25/03/2015 Pamiers Technical meeting with WP leaders AD
15/04/2015 Telcom Technical meeting with WP5 team AD
13/05/2015 Telcom Technical meeting with WP5 team AD
19/05/2015 Telcom Technical meeting with WP leaders AD
03/06/2015 Telcom Technical meeting with WP5 team AD
11/06/2015 Pamiers Review meeting AD+Topic Manager
01/07/2015 Telcom Technical meeting with WP6 team AD
29/07/2015 Telcom Technical meeting with WP6 team AD
01/09/2015 Les Ancizes Technical meeting with WP6 team AD
07/09/2015 Les Ancizes Technical meeting with WP6 team AD
30/09/2015 Pamiers Final meeting AD + Topic Manager

Consortium development

During the full project period, two major developments occurred. The information below summarized that:
- Additional work was defined
When the description of work was written, it was decided to check technical properties capability of larger ingot up to 25’’ diameter with the available AD730TM billets from Heat 1. And then, according to those results, it was planned to use only one kind of ingot to study the process cost (Heat 2). However, some properties issues were identified on 25’’ ingot from Heat 1. Reasons of that were identified to be independent of CESAME project. Consequently, in order to secure the project and to obtain reliable results, it was decided to study two AD730TM process (from two ingot sizes) with Heat 2. This study on a second AD730TM ingot was approved by the Topic Manager and the planning was updated to take into account this work.

- Budget shifts in direct costs and subcontracting
When CESAME budget was built, it was planned to subcontract the manufacturing of dies but after studying the offers of several subcontractors as it is usual practice for Aubert&Duval, the best cost compromise was to perform internally the manufacturing of dies in Aubert&Duval Les Ancizes plant.

In CESAME budget, it was planned to used material (10'' billets) available in Aubert&Duval for the manufacturing of parts from AD730 Heat 1 and U720Li (see description of WP4). Unfortunately, at the beginning of the project, the Topic Manager required that U720Li billet was not produced by Aubert&Duval but bought in order to compare AD730 with a reference material from the market

Due to accumulative delays of previous WP and busy production activity, it appeared during the project that the delay in WP4 could increase dramatically so in order to respect as much as we could the time-schedule, it was decided to speed up the process and used sub-contractors instead of performing these works (preparing of billet for close-die forging (cutting, machining...), machining of a part internally...) internally.

Project timetable
In order to take into account new deadlines validated by the Topic Manager, the project timetable was updated at the end of the first period and agreed with the Topic Manager.

Potential Impact:
CESAME project achieves to demonstrate that the new European superalloy, AD730TM, responds to the requirements of the aeronautic engine market in term of energy and cost saving.

Technical, economical and environmental benefits were reached with CESAME project and were described in the following paragraphs.

The latest design of high-efficiency engines has high requirements for the mechanical properties and temperature capability of the key components, especially the stages of disk where the stress and temperature are the highest. Alloy development for turbine disk with higher properties and temperature capability is consequently crucial in order to improve the thermal efficiency in gas turbine engines. The natural candidate material should be U720Li alloy or alloys of the same family for higher temperature applications. It is commonly admitted these alloys require isothermal forging which is quite expensive process. CESAME project has shown that the new European superalloy, AD730TM, is a suitable alternative to replace the classical U720Li alloy regards manufacturing process cost and properties.

Through CESAME project around 10 forged parts with same design were produced from AD730TM and U720Li materials. These parts were fully characterized and results showed that AD730TM final properties as mechanical properties and ultrasonic inspectability are similar and even higher than those obtained on U720Li parts. It was rigorously demonstrated that the new superalloy AD730TM is able to substitute U720Li. The new European grade, AD730TM, has so a legitimate place on the list of Cast & Wrought grades available for high temperature components of future aero-engines.

During the project, technical and cost saving optimizations of AD730TM process were performed and it was shown that isothermal presses are not required to forge such superalloy. It was also demonstrated that the use of larger ingots up to 25’’ diameter is possible with AD730TM alloy without any detrimental effect on mechanical properties. This new manufacturing route is so a step forward to reduce the AD730TM manufacturing cost regards U720Li. Thanks to CESAME project, it was demonstrated that an European company, Aubert&Duval, is capable of having a 100% integrated processing route for a new superalloy as AD730TM (to design, to melt, to forge) and so being a serious competitors on engine disks market regards international large companies based for example in United States or Russia. Aubert&Duval considers that the production of AD730TM alloy could reach in a middle term an annual budget of roughly 30M€ for the company and the results obtained on CESAME project is a major step to reach this objective.

Results obtained on AD730TM larger ingot (25’’) and reliable comparisons made with U720Li are really interesting and promising and will be so shared with the scientific community during an oral presentation on the Superalloy2016 conference which is a major conference on the Superalloys field.

Through CESAME project it was rigorously demonstrated that AD730TM can be manufactured with a lower process cost than U720Li. Consequently, the decrease of time production to convert AD730TM regards U720Li thanks to a better workability leads to a decrease in energy consumption and so a decrease in term of production of CO2 and NOx gases. Moreover, it was shown that melting of AD730TM is more prone to the integration of scraps material compared to U720Li. We expect so to recycle in the final industrial process 100% of AD730TM scraps.

CESAME project allowed to prove that the new European superalloy, AD730TM , is a suitable option for European engine manufacturers to use an innovative and up-to-date grade designed to have a robust, industrial and cost efficient process.

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Contatto

Coraline Crozet, (R&D PhD Engineer)
Tel.: +33 0473673762
Fax: +33 0473673266
E-mail
Numero di registrazione: 184738 / Ultimo aggiornamento: 2016-06-27