Weyhe, Germany
Weyhe, Germany

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Agency: European Commission | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2011-1-SAGE-05-015 | Award Amount: 1.07M | Year: 2012

The HEXENOR proposal aims to study, design and manufacture three items ( short, mean, and long) each made of two innovative concepts, a quiet plug and a quiet diffuser which will be mounted on a turboshaft engine to reduce the noise radiated by the exhaust. A preliminary study is concerned with the capability of two materials a Ferritic stainless steel (low cost material) and TiAl alloy (light but fragile material) to satisfy the design constraints and the engine hard conditions. High cycle fatigue, thermo-mechanical and metallurgical characterization tests will be conducted before the design step. Also an academic work will be achieved to determine an optimal configuration of a new quiet diffuser concept made of angular and axial cavities surrounding an internal perforated wall of the duct lined section. This approach is based on the measurement with a flow duct facility developed during the Ducat European program without and with cold flow of the liner configurations efficiency for a higher order mode incident pressure vector and the development of an analytical model of the acoustic propagation through the lined barrel leading to the calculation of the attenuation of each configuration with and without flow. The choice of the optimal configuration which will be used to design the quiet diffuser will be the result of a tradeoff between acoustic efficiency provided by the academic study, mass and cost specifications.

Kashaev N.,Helmholtz Center Geesthacht | Ventzke V.,Helmholtz Center Geesthacht | Horstmann M.,Helmholtz Center Geesthacht | Riekehr S.,Helmholtz Center Geesthacht | And 3 more authors.
Advanced Engineering Materials | Year: 2015

A fine-grained Ti-6Al-4V sheet that has been developed for superplastic forming (SPF) was joined to a standard Ti-6Al-4V sheet using a Nd:YAG laser and alloy compatible filler wire. The microstructural and mechanical properties of dissimilar laser beam welded butt joints were investigated to determine their behavior under static and cyclic loads and for SPF. The filler wire affected the heat input and reduced the increase in the hardness within the fusion zone compared to that in the heat-affected zone. The laser beam welding process activated local microstructure transformations that were associated with local changes in the microtexture, the β content, and the grain size. The mechanical behavior of a dissimilar laser beam welded butt joint under a static tensile load was controlled by the properties of the standard Ti-6Al-4V sheet. Laser beam welded specimens showed inferior fatigue behavior. Removing the geometrical notches did not significantly improve the fatigue behavior because local microstructural and microtextural changes still created metallurgical notches. SPF was observed in the fine-grained Ti-6Al-4V sheet without crack formation in the heat-affected zones or the fusion zone. The welding seam of the dissimilar fine-grained-standard butt joint was resistant to SPF. Microstructural and mechanical properties of laser welded butt joints between fine-grained (FG) and standard (STD) Ti-6Al-4Vare investigated to determine their behavior under static and cyclic loads and for superplastic forming. The effect of the strength mismatch is that the plastic deformation of the FG-STD butt joint is determined by the lower strength of the Ti-6Al-4VSTD base material. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Stutz L.,FormTech GmbH | Beck W.,FormTech GmbH | Arends S.,FormTech GmbH | Horstmann M.,Helmholtz Center Geesthacht | And 2 more authors.
Materialwissenschaft und Werkstofftechnik | Year: 2014

Titanium alloy sheets are widely used for highly loaded components in the aerospace industry as well as spacecrafts. The unique combination of high strength, outstanding corrosion resistance and thermal endurance makes titanium alloys the preferred material for applications with severe requirements. Due to the limited formability at room temperature, forming processes have to be conducted in a multitude of steps what is costly and labour intensive. Additionally, typical titanium alloy sheets show a significant anisotropy of mechanical properties and material flow. Undesired earing, wall thickness variation and residual stresses are the result. Complex shaped parts can be produced at elevated temperatures to avoid named drawbacks. The present work introduces a newly developed hot deep drawing process,applied to titanium sheets at FormTech. In comparison with conventional superplastic forming processes via gas pressure, hot deep drawing comes with a significantly reduced process time and hence, increased output over time. Titanium sheets of the work horse alloy Ti-6Al-4V were formed in a single stroke to a U-shaped component at process temperatures ranging from 750 to 890 °C. Specimens were extracted to validate the neglectable influence of the hot forming process on mechanical properties and fatigue behaviour. In conclusion, hot deep drawing of titanium sheets offers a cost efficient alternative to a gas pressure superplastic forming process, while maintaining its main benefits such as significantly improved formability, low residual stresses and tight tolerances. © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Formtech Gmbh and Rolls-Royce | Date: 2011-07-20

A method for manufacturing a workpiece 1, 2 uses a forming tool 4, 5 having a cavity 3. An embossing element 6 profiled on at least one surface is arranged on at least one surface of the forming tool 4, 5 for producing a surface structure, and with the profile of the embossing tool 6 is imparted to the surface of the workpiece 1, 2 during a forming process.

Formtech Gmbh and Rolls-Royce | Date: 2011-07-22

A compressor blade 1 of a gas-turbine engine has a flow-exposed leading edge 2. A component 3, made of wear-resistant material and featuring a higher erosive wear resistance than the base material, is attached to at least part of a length of the leading edge 2 The component 3 forming the flow-exposed leading edge 2 is strip-shaped, has an essentially rectangular cross-section and, with reference to a sectional plane perpendicular to the radial direction, is arranged only on an inflow side of the compressor blade profile in a partial area of a sectional surface of the inflow area.

Formtech Gmbh | Date: 2012-04-20

A method for processing at least one surface element wherein at least one layer of a deformable, medium-tight material is respectively attached to each side of the surface element, inserts the surface element and attached deformable layers between at least two molding tool parts and applies a pressure to at least one area of a surface section of the inserted surface element in response to a predetermined shaping temperature by introducing a medium between one of the deformable layers and a first molding tool part. The pressure acts directly against the deformable layer so that the surface element together with the deformable layers is shaped into at least one adjacent cavity of a second molding tool part due to the pressure created. A possibility of molding surface elements, which can currently not be shaped via gas pressure, into complex geometries, namely into spatially bent geometries, is created with this method.

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