Series production of Lightweight parts by Isostatic pressing of Metal powders to give Material and Energy Reduction (SLIMMER)
Lead Research Organisation:
University of Birmingham
Department Name: Mechanical Engineering
Abstract
A novel, sequential, net-shape process will be developed to enable complex, light-weight components to be created with minimum waste capable of supporting a wide range of production volumes. Metal powders are encapsulated in a complex-geometry reusable rubber tool and isostatically pressed. The resulting compacts are fully densified using a novel hot isostatic pressing (HIP) method that enables the densification of multiple green compacts into full density. Key innovations include novel tooling method to produce partially consolidated complex compacts and novel processing route to simultaneously consolidate multiple components to full density.
Planned Impact
Scientific / Technological / Economic benefits for companies
The immediate benefits are likely to be directly to the industrial end-users is the capability to use a novel manufacturing
process (bran tub), which generates lighter structures, with low cost tooling, and maximum material usage efficiency. In
addition, the activity based at UoB will provide the industrial end-users with computational modelling tools that minimise the
number of trials and iterations required to achieve the desired product quality and performance. The modelling tool will be
underpinned by sufficient scientific foundations, while making it flexible to be applied in an industrial context. Finally indirect
benefits are expected for a wider set of companies in the metals and ceramic processing sectors. This includes general
powder metallurgy, ceramics sintering, diffusion bonding, hot Isostatic pressing, powder injection moulding, etc... This may
well be through academic partners or catapult centres, which is one reason for wanting to publicise the research through
conferences that will attract both academic and industrial attendees.
Employment
The longer term benefits will be indirectly to the employees of the end-users, the university, and the UK supply chain (e.g.
powders, tooling, HIPping providers). This will help safeguard 100s of job opportunities across the UK. It will also generate
wealth through the development of new processes and products.
Society
The wider impact of this project on the society will be mainly focused on the reduction of material waste, energy usage, and
carbon footprint of manufacturing. The use of netshape powder processing will replace the conventional subtractive
manufacturing technologies, which are energy-intensive and result in material waste that can sometimes be difficult to
recycle. In addition, the reduction of the number of operations will also reduce the energy required for manufacturing.
Furthermore, the development of lightweight structures, specifically in the transport sector, will result in lower fuel
consumption and will reduce the carbon footprint of the transport sector overall.
Individuals
The project will also develop the skills of the future leaders in manufacturing research, by training 2 junior academics.
The immediate benefits are likely to be directly to the industrial end-users is the capability to use a novel manufacturing
process (bran tub), which generates lighter structures, with low cost tooling, and maximum material usage efficiency. In
addition, the activity based at UoB will provide the industrial end-users with computational modelling tools that minimise the
number of trials and iterations required to achieve the desired product quality and performance. The modelling tool will be
underpinned by sufficient scientific foundations, while making it flexible to be applied in an industrial context. Finally indirect
benefits are expected for a wider set of companies in the metals and ceramic processing sectors. This includes general
powder metallurgy, ceramics sintering, diffusion bonding, hot Isostatic pressing, powder injection moulding, etc... This may
well be through academic partners or catapult centres, which is one reason for wanting to publicise the research through
conferences that will attract both academic and industrial attendees.
Employment
The longer term benefits will be indirectly to the employees of the end-users, the university, and the UK supply chain (e.g.
powders, tooling, HIPping providers). This will help safeguard 100s of job opportunities across the UK. It will also generate
wealth through the development of new processes and products.
Society
The wider impact of this project on the society will be mainly focused on the reduction of material waste, energy usage, and
carbon footprint of manufacturing. The use of netshape powder processing will replace the conventional subtractive
manufacturing technologies, which are energy-intensive and result in material waste that can sometimes be difficult to
recycle. In addition, the reduction of the number of operations will also reduce the energy required for manufacturing.
Furthermore, the development of lightweight structures, specifically in the transport sector, will result in lower fuel
consumption and will reduce the carbon footprint of the transport sector overall.
Individuals
The project will also develop the skills of the future leaders in manufacturing research, by training 2 junior academics.
Publications
Mehmeti A
(2022)
Surface integrity of hybrid CM247LC/Inconel 718 components produced by laser-directed energy deposition
in The International Journal of Advanced Manufacturing Technology
Essa K
(2015)
An iterative approach of hot isostatic pressing tooling design for net-shape IN718 superalloy parts
in The International Journal of Advanced Manufacturing Technology
Abena A
(2019)
Comprehensive numerical modelling of the hot isostatic pressing of Ti-6Al-4V powder: From filling to consolidation
in Advanced Powder Technology
Abdelhafeez A
(2016)
Influences of Powder Compaction Constitutive Models on the Finite Element Simulation of Hot Isostatic Pressing
in Procedia CIRP
Description | Although we apply isostatic pressure on the tooling, the pressure transmitted to the powder is not isostatic due to the difference in the tooling stiffness. This explains the non uniform deformation and distortion found in densified components made by hot isostatic pressing. The tap density is not uniform and has a significant effect on powder densification and shape change. The optimum HIP cycle to successfully brantub 316l components has been obtained. |
Exploitation Route | The findings can help in the tooling design for complicated parts. It also indicated what is the right pressure, temperature and time that should be used to achieve the fully dense condition of a given material |
Sectors | Aerospace Defence and Marine Manufacturing including Industrial Biotechology Transport |
Description | To design a tooling for nickel based superalloy aerospace engine casing. That casing used to be fabricated by machining as such the by to fly ration was over 20. Being made by hot isostatic pressing, the by to fly ratio is reduced to 1.2. This shall lead to environmental impact by reducing material waste and carbon foot print as well as economical impact by reducing the manufacturing cost of aerospace casings |
Sector | Aerospace, Defence and Marine |
Impact Types | Societal Economic |
Description | EU-China RTD Cooperation UK |
Amount | € 455,000 (EUR) |
Organisation | European Commission |
Department | Horizon 2020 |
Sector | Public |
Country | European Union (EU) |
Start | 03/2016 |
End | 03/2018 |
Title | Finite Element Modelling of Hot Isostatic Pressing Process |
Description | Finite element model for Hot Isostatic Pressing using different materials models which include Gurson Porous Plasticity, Clay material model and Vicous Drucker Prager material model. |
Type Of Material | Computer model/algorithm |
Year Produced | 2015 |
Provided To Others? | Yes |
Impact | The work has been used to design a tooling for IN718 aerospace engine casing |
Description | Subcontracting Research Activity in EPSRC Funded Project |
Organisation | University of Manchester |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Develop finite element models for hot isostatic pressing of stainless steel powder. Find the optimum HIP cycle to get fully dense componet |
Collaborator Contribution | Provide powder, material properties and samples for charactrisation |
Impact | - A report shows the effect of HIP cycle on the densification of stainless steel powder - Journal papers will be produced from the obtained results |
Start Year | 2015 |
Description | Invited Speaker in King Saud University, Saudi |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | I gave one hour presentation about the work I have been doing about the numerical modelling of powder hot isostatic pressing and the impact of my work on the UK and EU aerospace industry. The talk was well attended by undergraduate, postgraduate, academic staff and policy makers in King Saud University. This followed by 30 minutes of open questions. A further collaboration was discussed and agreed after this talk |
Year(s) Of Engagement Activity | 2016 |
Description | Invited speaker in "2nd Mexican Workshop on Additive Manufacturing and 3D Printing" |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | I gave 30 minutes presentation about the research I have been doing in the area of additive manufacturing and hot isostatic pressing. The workshop was well attended by research scientist, public audience as well as industry. The presentation was followed by 10 minutes of open questions. A FARO Laser Scanner Arm was bough as a result of this event |
Year(s) Of Engagement Activity | 2015 |
URL | http://conferences.ncl.ac.uk/additivemx/abouttheworkshop/ |