SAMULET II Project 6: Powder Consolidation Technologies

In order to meet future engine performance requirements, this project was aimed at developing a new powder Hot Isostatic Pressure (HIP) process for the manufacture of combustor casings from new high temperature materials, enabling increased operating temperatures and pressures. Conventional forging of a casing from new alloys would be prohibitively expensive and this project aimed to reduce both the buy-to-fly ratio from 8:1 to 4:1 and machining costs by 70% for these complex aerospace components.

Additionally, this project aimed to develop an alternative technology to casting and forging/fabrication for Engine Section Stator (ESS) vanes, thereby, significantly reducing product introduction lead-times by 30% and enabling more complex 3D geometry for future engine designs.

This project also aimed to develop Metal Injection Moulding (MIM) technology for manufacturing compressor vanes enabling a reduction in the number of set-ups and machining operations. The current manufacturing processes for aerofoils traditionally employ a series of hot forming operations producing a forged aerofoil, followed by machining of the root features. The level of intermediary operations and set-ups between each forging and machining operation are labour intensive and can take up to 2 hours between each operation.

Download the SAMULET II Project 6: Powder Consolidation Technologies case study
Short Title: SAM 2 P6
Project Number: 110105
Project Cost: £10,066,998
End Date: 31st Dec 2015
Time Horizon: Secure
Lead Partner: Rolls-Royce PLC
Attributes: Fuel Efficiency
ATI Value Stream: Propulsion of the future