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Title: Flow forming of aeroengine materials
Author: Kubilay, Ceylan
ISNI:       0000 0004 5364 0589
Awarding Body: University of Manchester
Current Institution: University of Manchester
Date of Award: 2014
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Flow forming is a fairly new technique used for the production of dimensionally accurate near net shaped hollow components. The process has many advantages such as cost effectiveness and eliminating further operations like welding, machining, etc. This study focuses on the characterization of flow formed components to understand the process. Flow formed components are composed of different reductions and characterization techniques are applied to reveal the resulting microstructural differences. Effect of number of passes on the material is also investigated. Metallographic analysis was conducted by optical microscope, electron micro probe analyser (EPMA) and the electron back scatter diffraction technique (EBSD) in a scanning electron microscope (SEM). Texture evolution of the samples was examined either by laboratory X-ray diffraction or EBSD technique. Furthermore, residual stresses were measured by neutron diffraction (at StrainAnalyzer for Large and Small Scale Engineering Applications (SALSA) and PulseOverlap Diffractometer (POLDI) instruments), laboratory X-ray diffraction and hole drilling. Stress relief heat treatments were carried out at 500°C for either 4 or 16 hours to mitigate residual stresses without losing much of the strength. The experiments conducted show that flow forming is a process resulting in heterogeneous microstructure with grains elongated along the deformation direction. Texture evolution is different from the typical rolling of steels with body centred cubic crystal structure. Any significant effect of the number of passes was not observed. Due to the nature of the process, residual stresses in the axial and hoop directions are critical. Therefore, stress distributions through thickness of the samples are plotted. It is observed that in the thick section, the stresses are higher. Heat treatments applied at 500°C for 4 or 16 hours are effective in diminishing the stresses.
Supervisor: Preuss, Michael Sponsor: Rolls Royce plc
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available
Keywords: flow forming ; microstructure ; texture ; residual stress ; steel