Lightweight alloys forging future flight
Nickel-based alloys commonly used for aero engine turbine blades meet mechanical and thermal requirements but have relatively high densities. During recent decades, alloys of titanium and aluminides (gamma-TiAl alloys) with half the mass in a given volume have received attention as potential alternatives. Based on successful preliminary forging trials of a novel gamma-TiAl alloy containing niobium and molybdenum, scientists launched the EU-funded project DAFNE (Development of gamma-TiAl forgings in a low-cost near conventional hot-die process and process evaluation) to enable cost-effective production of low-pressure turbine blades. Using conventional forging equipment, project partners developed a slightly modified hot-die forging process that is low cost, meets manufacturer requirements and enables mass production of lightweight metals. Potential beneficiaries of project outcomes abound. Successful conventional hot-die forging of low-pressure turbine blades will decrease their cost by more than 75 %, opening new markets for DAFNE partners and creating jobs to offset the impact of the current economic crisis. The lower weight of the blades will facilitate faster rotation, increasing efficiency and decreasing fuel consumption and emissions, such that what is good for industry is also good for the environment.
Keywords
Alloys, low-density alloy, turbine blades, gamma-TiAl, DAFNE, hot-die forging