Hot stamping allows producing complex geometries from high performing materials. The use of this technique is increasing among automotive manufacturers because of the possibility to reduce weight without compromising with performance.

The aim of this study was to tailor the press hardening technique to fit the materials and demands of the turbofan engine, hoping to reduce weight, waste, machining and cost. Aerospace steel grades had not previously been used in press hardening. The possibilities and limitations of these new materials were thoroughly examined as well as the benefits using this manufacturing technique compared to conventional methods.

A selection of aerospace grade steels was characterised to find the material best suited for press hardening. For this material a thermo-viscoplastic material model was created. Using this model geometries from the turbofan engine, suited for press hardening, were optimised and the feasibility of forming these details investigated. The first of the geometries was a sheet metal disc. In this proposal it was suggested to also investigate one of the flow surfaces and a guide vane. To validate the simulation process and the prediction of detail quality from the forming analysis physical parts of the disc and the guide vane were produced.

For the disc and the guide vane benefits using near-net-shape blanks were investigated. A method to achieve non uniform blanks is rolling. Flat rolling is majorly done to produce a large amount of standard strip/plate. Flat rolling into a shape is not widely used but it has a large potential to save material and machining by rolling a Near-net-shape product. The guide vane was manufactured using this technique.

Also, a technical study of serial production was performed to compare the new production process to conventional design and manufacturing methods with regards to detail quality, weight, cost, material properties and manufacturing robustness.