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Development and validation of a powder HIP route for high temperature Astroloy to manufacture Ultrafan® IP Turbine Casings

Project description

Testing the performance of a promising superalloy for use in UltraFan engines

The demand for improved gas turbine engine efficiency has been driving the development of higher-performance materials that can withstand very high temperatures. Superalloys are highly attractive for use in high-temperature applications as they can retain high strength, stability, and corrosion and oxidation resistance. The EU-funded HUC project will deal with the manufacture of intermediate-pressure turbine casings for the new-generation UltraFan engine. The manufacturing process consists of the high-pressure and high-temperature pressing of a powdered superalloy called Αstroloy, which enables significant reductions in energy consumption compared to the traditional method using a forge. Using Αstroloy, HUC’s main objective is to improve the buy-to-fly ratio from 9 (achieved through conventional manufacturing routes) to less than 3.


This is a response to the Call for Proposal under Clean Sky 2 and JU to manufacture IP Turbine casings for the new generation Ultrafan® engine from Astroloy using Net Shape Hot Isostatic Pressing of powder (NSHIP).
Astroloy with high γ’ volume fraction have the required high temperature properties but it is unforgeable. Thus, Powder-HIP is the most promising process route for this alloy though this technique presents several challenges such as presence of PPBs in the HIPped microstructure, the high cost of powder and HIP-tooling. HUC, making usage of the background technology will face and overcome these challenges and will take a step further tackling technology gaps alongside the material capability, basic mechanical behaviour and impact in the presence of the exposure with the ultimate goal for this technology to be fully tested in the relevant UltraFan® Demonstrator engine environment.
The main objective of HUC is to improve the buy to fly ratio from the typically achieved 9 through the conventional cast and wrought route to less than 3 through NNSHIP being the material developed able to withstand engine relevant conditions with and without exposure guaranteeing its ability to contain. The work plan includes the following main activities:
1. Development and Optimisation of a powder HIP processing for Astroloy
2. Characterisation of mechanical properties to generate a database which supports the component design
3. Development of experiments and numerical simulations to assess the material´s behaviour under dynamic and ballistic conditions
4. Characterisation and understanding of mechanical properties with exposure at high temperatures
5. Development of low cost tooling for HIPping high temperature superalloy casings
6. Development and validation of process modelling capabilities
7. Manufacturing of canning/tooling to guarantee the compliance of the finish product with the requirements
8. Project progress Management, Dissemination, Communication and Exploitation


Net EU contribution
€ 667 836,25
Paseo manuel de lardizabal 15
20018 San sebastian

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Noreste País Vasco Gipuzkoa
Activity type
Research Organisations
Other funding
€ 0,00

Participants (4)