Modelling Aspects in Forming and Welding of Nickel-Base Superalloys

The reduction of fuel consumption and carbon dioxide emissions are currently a key factor for the aviation industry because of major concerns about climate change and more restrictive environmental laws. One way to reduce both fuel consumption and CO2 emissions is by significantly decreasing the weight of vehicles while increasing the efficiency of the engine. To meet these requirements, the European aero-engine industry is continuously focusing on improved engine designs and alternative manufacturing methods for load-carrying structures in advanced materials, such as titanium and nickel-base superalloys. These new manufacturing methods involve sheet-metal parts, small castings, and forgings assembled using welding, enabling flexible designs where each part is made of the most suitable materials and states, with advantages such as reduced product cost, lower weight, and increased engine efficiency. In this thesis, a manufacturing process chain including forming and welding in two nickel-base superalloys, alloy 718 and Haynes® 282®, is studied. The aim of this work is to determine which aspects within the material and process are the most relevant to accurately predict the amount of shape distortions that occur along the manufacturing chain. The effect of the forming temperature on the predicted springback is included. The results are compared with experimental cold and hot forming tests with a subsequent welding procedure. During forming of a double-curved component in alloy 718 at room temperature, open fractures are observed in the drawbead regions, which could not be predicted while evaluating the formability of the material based on Nakazima tests and forming limit curves (FLC). The generalised incremental stress-state dependent damage model (GISSMO) is calibrated and coupled with the anisotropic Barlat Yld2000-2D material model to accurately predict material failure during forming using LS-DYNA. The mechanical properties of alloy 718 are determined via uniaxial tensile, plane strain, shear, and biaxial tests at 20 °C. The deformations are continuously evaluated using the digital image correlation (DIC) system ARAMIS™. Numerical predictions are able to accurately predict failure on the same regions as observed during the experimental forming tests. Comparisons of the distribution of damage on one of the drawbeads, between simulations and damage measurements by acoustic emission, indicate that higher damage values correspond to bigger micro cracks. The