Digital Transformation using Predictive Analytics for Near Net Shape Powder Metallurgy Hot Isostatic Pressing Smart Manufacturing

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Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 35865

Start date and planned duration: March 2024, 36 months

Objective

The development of digital tools will help to improve the following aspects of parts manufacturing using Near Net Shape Powder Metallurgy Hot Isostatic Pressing (NNS PM HIP) technique:

Predictive analytics tools will allow to reduce the required number of HIP trials in order to achieve the desired shape/properties
Achieve a better process efficiency in order to reduce material wastage and energy consumption
Create a correlation between input factors (powder characteristics, canister geometry, fill & outgas, HIP process parameters etc.) and output factors (microstructure, final shape, properties etc.)
Aid the development of standard operating procedures for a wide variety of materials and parts geometries

Project Outline

The main motivation for digitalisation in NNS PM HIP is associated with the extensive amount of variables present in the process, and the need to achieve a precise control over the manufacturing process and operations with consequent decrease in scrap loss. Moreover, it can also help in achieving the shape of the final part in near net-shape form with properties comparable to the wrought material. NNS PM HIP variables can be divided into several main categories, such as the feedstock powder production route, powder characteristics (chemical, physical), canister design & manufacture, powder fill & outgassing operations, HIP consolidation parameters, post-HIP operations e.g. machining, heat treatment (HT), microstructure and mechanical properties, and within each category are a whole host of sub-variables.

Digital transformation using predictive analytics will help in identifying relationships between different input variables which can guarantee a future product with the desired shape and final properties.

Industry Sectors

NNS PM HIP technique is widely used in industry for the manufacture of engineering components across multiple industrial sectors including but not limited to Nuclear/fusion, Oil&Gas, Space & Aerospace, Defence, Marine, Industrial machinery, etc.

Below are few examples of the benefits and use of PM HIP for some specific industrial sectors:

- Power - Fusion for the manufacture and joining of refractory metals and oxide dispersion strengthened (ODS) steels

- Aerospace, achieving a better buy-to-fly ratio with superior mechanical properties

- Oil and Gas to reduce the number of welds in super duplex components

- Submarine, manufacturing of large pressure vessels

Benefits to Industry

Industry is currently experiencing several issues (long supply chain length and lead time, geometrical limitations, etc.) during conventional manufacturing processes such as casting, forging, machining and welding. Moreover, a progressive increase in operating conditions, parts design complexity with minimal material wastage are the limiting factors for the conventional manufacturing processes.

Thus, the use of NNS PM HIP manufacturing process can represent a valid alternative to manufacture high performance complex engineering components. Although NNS PM HIP manufacturing technique can benefit multiple industrial sectors, however, this technique involves several complex processing steps. Each step has a crucial role on the final microstructure and properties of hot isostatically pressed (HIPed) parts. This project will aim to collect key data for each processing step and implement digital tools to aid improving the process efficiency and repeatability with consequent lower parts rejection.