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Development and validation of a powder HIP route for high temperature Astroloy to manufacture Ultrafan® IP Turbine Casings


Development and validation of a powder HIP route for high temperature Astroloy to manufacture Ultrafan® IP Turbine Casings

Call for proposal: 
Link to CORDIS:
Background & policy context: 

This is a response to the Call for Proposal under Clean Sky 2 and JU to manufacture IP Turbine casings for the new generation Ultrafan® engine from Astroloy using Net Shape Hot Isostatic Pressing of powder (NSHIP).

Astroloy with high γ’ volume fraction have the required high temperature properties but it is unforgeable. Thus, Powder-HIP is the most promising process route for this alloy though this technique presents several challenges such as presence of PPBs in the HIPped microstructure, the high cost of powder and HIP-tooling. HUC, making usage of the background technology will face and overcome these challenges and will take a step further tackling technology gaps alongside the material capability, basic mechanical behaviour and impact in the presence of the exposure with the ultimate goal for this technology to be fully tested in the relevant UltraFan® Demonstrator engine environment.


The main objective of HUC is to improve the buy to fly ratio from the typically achieved 9 through the conventional cast and wrought route to less than 3 through NNSHIP being the material developed able to withstand engine relevant conditions with and without exposure guaranteeing its ability to contain. The work plan includes the following main activities:

  1. Development and Optimisation of a powder HIP processing for Astroloy
  2. Characterisation of mechanical properties to generate a database which supports the component design
  3. Development of experiments and numerical simulations to assess the material´s behaviour under dynamic and ballistic conditions
  4. Characterisation and understanding of mechanical properties with exposure at high temperatures
  5. Development of low-cost tooling for HIPping high temperature superalloy casings
  6. Development and validation of process modelling capabilities
  7. Manufacturing of canning/tooling to guarantee the compliance of the finish product with the requirements
  8. Project progress Management, Dissemination, Communication and Exploitation
Institution Type:
Institution Name: 
European Commission
Type of funding:
Programme Other: 
JTI-CS2-2017-CfP07-ENG-03-22 Development and validation of a Powder HIP route for the manufacture of the UltraFan® Demonstrator IP Turbine casing from high temperature material allowing product enhancements at significantly lower costs and environmental
Lead Organisation: 

Asociacion Centro Tecnologico Ceit-Ik4

Paseo Manuel De Lardizabal 15
20018 San Sebastian
EU Contribution: 
Partner Organisations: 

Fundacion Imdea Materiales

Calle Eric Kandel 2 Parque Cientifico Y Tecnologico Tecnogetafe
28906 Getafe
EU Contribution: 

Aubert & Duval Sas

75015 PARIS CEDEX 15
EU Contribution: 

Consorzio Interuniversitario Nazionale Per La Scienza E Tecnologia Dei Materiali

Via Giusti 9
EU Contribution: 

Universidad Del Pais Vasco/ Euskal Herriko Unibertsitatea

Barrio Sarriena S N
48940 Leioa
EU Contribution: 
Development phase: