SBIR-STTR Award

he proposal addresses the development of the efficient technology for critically loaded engine components such as static and rotating parts of turbo-machinery from high strength and environment compatible Ni and Fe-based superalloys. Phase 1 will result in the development of the advanced process model for HIP of complex "net shape" engine components and demonstration of the "anisotropy" module within the entire model. Also a viability of the proposed technology will be proven by developing and manufacturing of a complex shape subscale demo of the critical engine component. The advancement towards "net shape" can be found in a combination of advanced manufacturing techniques and process modeling methodology research and development. The proposed steps to highly desirable "net shape" products are advances to existing process models used to design HIP tooling. The advanced modeling will attempt to fully account for plastic and creep deformation of compressible powder media interacting with solid HIP tooling as well as the evolution of material properties during HIP cycles. The improved model will be based on powder rheology and account for inherent anisotropy caused by the evolution of pores during consolidation. Phase 1 will develop the advanced process model for HIP of complex "net shape" engine components and demonstrate an "anisotropy module" within the model. There will also be a hardware demonstration of the proposed technology with a complex shape subscale segment of a critical engine component (a turbo-pump impeller or housing are candidate parts). Upon the successful completion of Phase 1, a second Phase could use the developed model and process to develop and produce acceptable examples of rotating and static liquid rocket engine components for rocket engine components. Boeing-Rocketdyne, for one has expressed a strong interest in this development. The expected cost and cycle reduction of 30-50%, when compared to investment castings or machining from rough shapes, will be demonstrated during this phase. Potential commercial applications of the R&D can also include net shape aircraft components, HIP-cladded valves for chemical petroleum recovery and refining, and medical implants

The proposal addresses the development of a novel, efficient manufacturing technology demonstrated during Phase 1. This novel technology has clearly shown specific benefits to critically loaded components of liquid rocket engines using advanced process modeling and computer aided design. Examples of these critically loaded components that will be fabricated are static and rotating parts of turbo-machinery from high strength and environmentally compatible Ni and Fe-based superalloys as well as Ti alloys. A deliverable of Phase 2 will be engine component prototypes with acceptable properties, predictability and repeatability for Boeing-Rocketdyne. The process to manufacture fully dense, complex shaped products is based on a novel "selectively net shape" approach developed, and routinely employed by Synertech P/M utilizing advanced technologies such as Hot Isostatic Pressing of powders (HIP), Computer Aided Design (CAD) and Direct Metal Fabrication (DMF) of HIP tooling. A necessary constituent of this approach is advanced process modeling that enables significant reduction of development and manufacturing costs by as much as 30-50% due to the innovative prediction of material behavior during powder processing.

Keywords:
NET SHAPE, POWDER, HIP, PROCESS MODELING, FULLY DENSE, ANISOTROPHY, ATOMIZED POWDERS