Super Thin Near Net Shapes Christophe DELAUNAY Pierre MÜNCH

Transcription

1 Super Thin Near Net Shapes Christophe DELAUNAY Pierre MÜNCH ITA

2 CEFIVAL SIDERVAL HOESCH SCHWERTER PROFILE GmbH FALCI srl ITA

3 CONTENT 1) Technical capability assessments 2) Identification of the first potential component part 3) Calculation of cost and weight savings 4) Process route 5) First Tests done on the extruded part 6) Results carried out and comparison with objectives 7) Tests achieved successfully on the machined part ready to be assembled : Machining time reduced, BTF =2, lead time optimized 8) Extrusion technology mixed to other technology : Linear friction welding or Bending ITA

4 Technical capability assessments Usual extrusion Process BTF = 6 Due to the hot process Reachable thickness is usually around 7-10 mm 0.27 up to 0.40 Tolerances on long length are minimum ± 0,5 mm - ± 0,02 or ± 1% Is it possible to reduce the thickness keeping the same level of tolerances on the overall length? What could we achieve? Thickness could be reduced at half of the today s levels. ITA

5 Technical capability assessments How to achieve it? Utmost importance of Stiffness achieved with compact extrusion press design High level of homogeneity on temperature will be necessary. Lubrication and tooling Processes have to be adressed to ensure steady tolerances on the overall length for twist straightness angles flatness Heat treatment Surface Smoothness and Alpha Case Free ITA

6 Identification of the first potential component part Start-up of the project decided with non aerospace profiles in 2007 as a first trial on our old extrusion press trials done on the new extrusion press with various titanium grades Issue was to find a part complicated enough to understand the limits of the extrusion process Project carried out in 2010 with the support of Airbus on a prototype of a seat track 2007 Trial Ta6V ITA

7 Calculation of cost and weight savings Approximate Original Shape Weight : 11,5 kg/m 7,4 lbs/ft Calculation has shown potential improvement on wings thickness without deteriorating the overall straightness and the smoothness of the product Super Thin Near Net Shape Weight Obtained : 5,8 kg/m 3,9 lbs/ft Weight Savings = 5,7 kg/m 3,5 lbs/ft Savings per aircraft > 1100 kgs 2400 lbs ITA

8 Calculation of cost and weight savings done - Original Machining Time estimated : 5 hours A350 Potential Seat Track Weight Improvement : 5,8 kg/m 3,9 lbs/ft Machining time Savings per meter = 45 mn using a 8:1 method (2 in 3 /mn) Machining time savings per aircraft = 150 hours + Transportation costs savings + Environmental Costs savings Savings estimated per aircraft = 2400 lbs hours machining time ITA

9 The Compact Extrusion Press ITA

10 Induction Billettes The Process Route F O U R S Homogeneisation Compact extrusion press Ram Billet Finishing Operations Optimized lubrication Container Mandrel Glass pad Toolings Calibration Automatic repair ITA AUTOMATIC TOOLING LINE

11 First Tests done on the extruded part 2007 First trials on the old extrusion press 2009 After set-up of the new extrusion press in 2008, trials on various titanium grades ITA

12 First 2007 Trials on a non aerospace shape on the first (old) extrusion press 65 X 30 X 3 mm - 2,56 X 1 1/8 x 1/8 Tests carried out on Grade 9 (Ta3V2.5) and Grade 5 (TA6V) Mechanical characteristics are OK Difficulty to maintain the tolerances on the overall length Grade Re0,2% Rm A Z MPa MPa % % TA6V TA6V TA3V2, ITA

13 2009 Second trial on an aerospace shape using the new compact press Tests carried out 80 X 75 X 3.5 mm 3 1/8 X 3 X 1,3 On grade 5 and grade 2 ITA

14 2009 Second trial on an aerospace shape using the new compact press (2) Grade 2 // T40 Grade 9 // TA3V2.5 transvers 0 to 1 6 longitudinal 3 A 5 5 longitudinal 3 A 5 5 A 6 Tests carried out 80 X 75 X 3.5 mm 3 1/8 X 3 X 1,3 On grade 5 and grade 2 No differences in the young modulus Results done with LPMTM // CNRS Institut Galilée, Université Paris 13 ITA

15 2009 Second trial on an aerospace shape using the new compact press (2) Tests carried out 80 X 75 X 3.5 mm 3 1/8 X 3 X 1,3 On grade 5 and grade 2 U.T.S YS Elongation E MPa MPa % GPa ASTM B START END ITA

16 Results carried out and comparison with objectives ITA

17 Typical extruded TA6V «Alpha Beta» «Beta» Typical requirements Longitudinal Typical requirements Longitudinal Re > 830MPa A > 10% Re > 830MPa A > 10% Rm > 930MPa Z > 25% Rm > 900MPa Z > 20% Transversal Transversal A > 10% A > 8% Z > 20% Z > 15% Typical toughness between 55 and 80 MPa.m 1/2 ITA

18 Final results on mechanical characteristics and structure TA6V U.T.S. YS Elongation % E MPa MPa % Gpa requirements start long end long Super Thin Near Net Shape ITA

19 Final results on Super Thin Near Net Shape 3mm / ailette centrale Strong thickness reduction tolerances maintained ITA

20 Tests achieved successfully on the machined part : 45 mn Machining time reduction ITA

21 Extrusion technology associated to other technology such as linear friction welding or bending have shown as well great benefits. BTF reduction routes using combined technologies are in process. ITA

22 2011 Combined technologies trials Linear friction welding of wings Done by ACB Wings after machining Machining on a PIOCH machine ITA

23 Thank you for your attention ITA