Unique supply chain for hot fomed and welded aero engine components

Load carrying aero engine components made of nickel-based superalloys such as alloy 718 or Haynes 282 include sheet metal geometries that are welded together with forging and castings into complete structures. The complex manufacturing process is called fabrication.  In order to efficiently and successfully produce components within tolerance, the method needs to be studied and process optimized through simulation.

Only a handful flight-approved subcontractors according to AS9100 exists in Sweden today. This project gathers expertise from two of these flight-approved SMEs, Rydverken and Brogren Industries, in order to study and demonstrate a highly advanced manufacturing process that includes hot forming and welding of so-called sub-assemblies. Such structures are of interest to GKN Aerospace Sweden. Brogren Industries, produce components for sub-assemblies, so-called vanes in which cold formed and welded geometries are delivered to GKN. Hot forming is an interesting and sometimes necessary process to minimize both shape distortions and material consumption. A successful project, where hot forming is part of the manufacturing chain, paves the way for future business where this new highly specialized supply chain can take on production that is unique in Europe. The project studies the potential for hot forming to achieve excellent shape tolerances in which non predictable shape deviations arising during cold forming can be eliminated, new collaboration between SMEs is created which together with RISE can provide the aero engine industry unique expertise, added value in the form of simulation results to subsequent manufacturing simulation and production in Sweden.