Master's thesis; Calibration of a stress relaxation model for development of sustainable hot forming in Ti-6242

Background
This project offers a unique opportunity to contribute to the future of the Aero engine industry by revolutionizing the hot forming process for Aero engine components. Currently, these components are produced through traditional methods that are expensive, time-consuming, and energy- intensive, often resulting in significant material waste. Traditional hot forming techniques require large ovens and specialized tools that degrade quickly, leading to frequent replacements and inefficiencies. In previous research, innovative concepts using FE-analyses have shown promising results in optimized forming conditions, particularly for titanium and nickel-base superalloys.

However, some challenges remain for the method to reach industrial implementation. In particularly, tool material degradation and wear together with energy consumption need to be reduced. RISE, GKN Aerospace, Brogren Industries, MagComp and KG Fridman AB are working together to overcome these challenges by exploring new methods of heating the sheet metal directly to the desired temperature, bypassing the need to heat the entire forming tool. This approach could reduce energy consumption by over 90%, minimize material waste, CO2 emissions and enhance industry competitiveness. By joining this project, you will collaborate with industry leaders and researchers to drive the adoption of these groundbreaking technologies, contributing to a more sustainable and efficient aviation industry.

Description
The project is structured into several key activities, each designed to advance the development of innovative hot forming technology. The journey begins with identifying a suitable demonstrator geometry and selecting components of commercial interest. The appropriate sheet alloy, tolerance requirements, and possible process parameters will be determined. Next step, will explore potential non-metallic tooling materials, narrowing down to two ceramic variants for evaluation. The design of test specimens and demo tools will also take place. Another activity focuses on creating an induction coil solution tailored to the demo tool, ensuring effective direct heating of non-magnetic aerospace materials. When these steps are finished it’s time for the experimental activities, where specimen geometries of the ceramic tool material are tested and evaluated of compression performance under conditions relevant to commercial hot forming. Next phase involves manufacturing of the demo tools and carrying out induction heating and hot forming tests. The heat distribution will be evaluated, assess the impact on tooling materials, and analyzing shape deviations for the demonstrator geometry, focusing on the two selected material solutions. One activity will focus on assessing the sustainability gains and any potential drawbacks compared to current hot forming methods. This includes detailing how the new tooling concept can contribute to net-zero production in a realistic scenario. This comprehensive approach ensures that each aspect of the project is meticulously managed and contributes to groundbreaking advancements in hot forming technology.

The thesis work will focus on calibrating material parameters in a stress relaxation model based on performing hot tensile tests. This model can be used to predict the springback in the hot forming process by performing a FE-simulation. Also, the student will participate in experimental activities related to evaluating the performance of the non-metallic tool materials and contribute to the evaluation of the hot forming tests.

Key Responsibilities
As a master’s thesis student, your role will involve contributing to cutting-edge research in hot forming technology. Specifically, your work will focus on three critical areas:

1.      Material Demo-Testing:

• Be involved in performing hot stress relaxation tests, from which the results are used to determine the material parameters in a stress relaxation model. The model can then be applied in a Finite Element Analysis (FEA) of the hot forming process.

• Conduct material demo tests to evaluate material performance under selected conditions relevant for hot forming in the production of commercial components.

2.      Hot-forming experimental Test:

• Be involved in the design of hot forming demo tools.

• Conduct induction heating and hot forming tests.

• Evaluate heat distribution in the part.

• Assess the impact on tooling material.

• Analyze shape deviations of the demonstrator geometry and compare with FE-model predictions.

• Testing will be carried out for the two material solutions within this activity.

You will be part of a research team at RISE in Olofström working with the research project and collaborating with GKN Aerospace Sweden.

Qualifications

To be a candidate for this master’s thesis project, you would need the following qualifications:

• Enrolled in a master’s program in Materials Science, Mechanical Engineering, Aerospace Engineering, or a related field.

• Understanding of Material Science: Familiarity with the properties and behavior of materials, especially metals, under various conditions.

• Mechanical Testing: Have the ability to adopt skills during supervision, in conducting relaxation and compression tests and other mechanical evaluations to assess material behavior.

• Induction Heating and Hot Forming: Understanding of or willingness to learn about induction heating processes and hot forming techniques.

• Data Analysis: Ability to analyze experimental data, particularly in evaluating the stress relaxation behavior in titanium, heat distribution, material impact, and shape deviations.

• Innovation: Interest in contributing to cutting-edge research and pushing the boundaries of existing technologies.

• Attention to Detail: Precision in assisting when experiments are conducted and analyzing results, ensuring accuracy in the research outcomes.

• Teamwork: Ability to work collaboratively with a research team, including participation in the design and evaluation phases of the project.

• Communication Skills: Proficiency in documenting results and presenting them clearly to the project partners.

This combination of technical expertise, analytical skills, and collaborative abilities will enable you to perform the Master thesis and contribute to the research on hot forming technology.

Responsibilities

Student Responsibilities:

• - Conduct independent research and analysis

• - Design and execute experiments in collaboration with RISE researchers

• - Perform theoretical studies independently.

• - Maintain regular communication with the supervisor.

• - Document all findings and progress.

• Adhere to deadlines for thesis drafts and final Submissions

Supervisor Responsibilities:

• - Provide guidance and feedback on research direction.

• - Offer support in methodology and technical aspects.

• - Design and execute experiments in collaboration with the Master thesis student.

• - Review drafts and provide constructive feedback.

• - Ensure the student remains on track to meet deadlines

Terms
Confidential Information: The student will sign a NDA to get access to specific information.
Location: Olofström
Start date: January 2025
Scope: 30 hp
Remuneration: 30 000 SEK after finalized thesis. 

Welcome with your application!
If you have any questions, please contact Martin Ohlsson (martin.ohlsson@ri.se). The application deadline is December 8, 2024.