FAST-forge of AM metal-metal composites

Critical aerospace components manufactured from titanium alloys and nickel superalloys tend to be over engineered due to the restrictive melt-wrought-machining route. Even powder processing routes utilising hot isostatic pressing for nickel superalloys have limitations due to the requirement of downstream thermomechanical processing.

Over recent years hydrid powder consolidation processes FAST-forge and FAST-DB have demonstrated that titanium and nickel superalloys powders can be consolidated and forged in two steps to produce near net shape demonstrator parts such as rocker arms and connecting rods. Higher strength (and higher cost) alloys can be graded into different subcomponent regions to provide cost effective subcomponent or site specific properties.

In this project, through EPSRC MAPP partners we aim to create a new processing route that will combine FAST-forge and AM technologies. [Step 1] Rapid laser AM methods will be used engineer intermediate lattice structures that will be [Step 2] embedded with a range of powder chemistries /morphologies in a shaped graphite mould and rapidly sintered using FAST into a shaped metal-metal composite billet. The aim of this step is to diffusion bond the metal AM lattice structure to the matrix through the solid state FAST process. The fully consolidated FAST metal-metal composite billet will then be [Step 3] hot closed-die forged to provide unique mechanical properties. The lattice metal-metal matrix will be engineered so that after the forging deformation will provide subcomponent specific properties. It is envisaged that this will provide a disruptive shift in the design and processing of critical components for a range of sectors.