The objective of this project was the implementation of an integrated simulation chain including pre material characteristics, thermo-mechanical processing (forging and heat treatment) and assessment of microstructure and functional properties for aerospace turbine components.

The integration of different computational results within an interdisciplinary and intercompany design-chain was a challenging task. A fully integrated simulation chain along the supply chain will give unique benefit for product development with respect to time, cost, and quality. This allows an optimisation of the forgings in respect of weight, efficiency and CO2 reduction.

Böhler Schmiedetechnik GmbH & Co KG (BSTG) developed a model for determining the microstructure (e.g. local grain size distribution in a component) from forging and heat treatment simulations. This model was in daily use for thermo-mechanical process design and optimisation of turbine disks. In past, recent and future R&D projects, Böhler Schmiedetechnik had developed models for determining the local functional properties depending on the microstructure. In a further step, aiming at the topic of this proposal, the simulation chain is to be integrated into an industrialised useful format, targeted at customer needs. Suitable strategies and methods for integration of the pre-material characteristics had to be assessed. The quality of the existing models had to be evaluated together with the customer. Comprehensive statistic investigations work was necessary in order to make the usage of the simulated data possible at the customer. Detailed investigations had to be executed to improve and/or generate functional properties models like yield stress, low cycle fatigue and creep models. Interfaces had to be defined and generated. A validation work had to be examined with forged LPT (low pressure turbine) demonstrator disks which show the effectiveness and model capabilities.