Descripción del proyecto
Probar el rendimiento de una superaleación prometedora para motores UltraFan
La demanda de mejorar la eficacia de los motores de turbinas de gas ha espoleado el desarrollo de materiales con un mayor rendimiento que puedan soportar temperaturas muy altas. Las superaleaciones son muy atractivas para su uso en aplicaciones de alta temperatura, ya que pueden conservar una gran resistencia, estabilidad y resistencia a la oxidación y la corrosión. El proyecto HUC, financiado con fondos europeos, se centrará en la fabricación de carcasas de turbinas de presión intermedia para el motor UltraFan de nueva generación. El proceso de fabricación consiste en el prensado a alta presión y alta temperatura de una superaleación en polvo denominada Αstroloy, que permite reducir de forma notable el consumo de energía en comparación con el método tradicional de forja. Mediante el empleo de Αstroloy, el objetivo principal de HUC es pasar de una relación entre el material total inicial y el material final usado de nueve (conseguida con las vías de fabricación convencionales) a menos de tres.
Objetivo
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
Ámbito científico
Programa(s)
Régimen de financiación
CS2-IA - Innovation actionCoordinador
20018 San Sebastian
España