Hard to Deform Materials
Proposal for hot roll-forming of axially symmetric parts out of hard to deform materials.
Tech Area / Field
- MAT-ALL/High Performance Metals and Alloys/Materials
8 Project completed
Senior Project Manager
Kondratenkov Yu B
Russian Academy of Sciences / Institute of Metals Superplasticity Problems, Russia, Bashkiria, Ufa
- VNIITF, Russia, Chelyabinsk reg., Snezhinsk
- Rockwell International Corporation / Rockwell Science Center, USA, CA, Thousand Oaks\nSnecma Moteurs / Direction de Production-LAY, France, Evry\nLos-Alamos National Laboratory, USA, NM, Los-Alamos
Project summaryA novel process has been developed by the Institute for Metals Superplasticity Problems (IMSP) in Ufa, Russia for low cost, rapid and highly flexible manufacturing of large gas turbine engine discs. This disc roll-forming process (DRF) was developed at IMSP to the prototype production stage as a novel solution to the problem of rapid and flexible manufacturing of gas turbine engine discs in times of military emergency. The project was the most strategically important project at the institute until the military funding ceased (~ 1990). It has recently also been demonstrated, with funding from Rockwell, that this technology can fabricate higher quality lower cost aluminum automotive wheels compared to conventional methods and is potentially attractive for a wide range of axi-symmetric components in both automotive and aerospace applications.
A full scale prototype manufacturing line for roll-forming gas turbine engine discs, designated "ALPD-800," has more recently been fabricated (at Ufa in Russia), but remains unassembled in crates due to the cancellation of the former Soviet military project. This project will set up the ALPD-800 at the Chelyabinsk-70 nuclear weapons laboratory and perform demonstrations and evaluations for three generic end-uses, namely gas-turbine engine discs, rocket engine turbo-machinery discs and automotive components such as wheels, brake rotors and brake drums.
Although roll-forming and the related process of spin-forming are not new, the unique features of the IMSP approach are the integration of work-piece pre-processing and the roll-forming process into an overall scheme for total control and exploitation of microstructure evolution and metal flow in the workpiece. The process allows precise control of shape in a controlled strain rate, hot deformation process under low working stresses and with simple rollers in place of tool and die sets.
The team has been carefully chosen to provide the necessary technical, business, and marketing support for successfully meeting the ISTC goals. The US participants may include several of Rockwell International's operating pisions as well as the Science Center for materials technology, Rockwell's Automotive Operations and Rocketdyne Division for applications, and Rockwell's Allen-Bradley for factory automation technology. Russian participants include IMSP, developers of the technology, and the Russian Federal Nuclear Center — All-Russian Scientific Research Institute of Technical Physics (ARSRITP) and The Association of Enterprises "Uralform" (AE "Uralform") both of Chelyabinsk-70.
The Rockwell Science Center has already been actively involved in practical evaluations of related IMSP technology through Rockwell funded projects. This ISTC project will provide the seed funding to set up a local product development and manufacturing facility employing engineering and technical specialists from the weapons and nuclear development complex. Rockwell will contribute to the program planning, coordination, application surveys, product evaluation and marketing. Rockwell anticipates that this project will form the basis for long term continued collaboration between Rockwell and the Russian participants and will enable further research and development to be performed in this advanced metal forming technology.
This two-year project has well defined goals consistent with the schedule and funding. The overall plan has been carefully structured with separate but related subtasks, intermediate milestones, and major project reviews. This plan will allow the ISTC to continually monitor progress to ensure that the project will meet each of its goals. This project will continue technical and business relationships which currently exist between each of the participants. Overall project management will be with IMSP in Russia.
This project will help the ISTC achieve its objectives of
• aiding the transition to a market based economy by integrating Western marketing knowledge into Russian commercial production technology;
• supporting technology development for peaceful purposes by using the military production technology for production of commercial products such as car wheels;
• promoting integration of weapons scientists into the international scientific community by utilizing nuclear scientists and engineers from Chelyabinsk-70.
The International Science and Technology Center (ISTC) is an intergovernmental organization connecting scientists from Kazakhstan, Armenia, Tajikistan, Kyrgyzstan, and Georgia with their peers and research organizations in the EU, Japan, Republic of Korea, Norway and the United States.
ISTC facilitates international science projects and assists the global scientific and business community to source and engage with CIS and Georgian institutes that develop or possess an excellence of scientific know-how.