The objective of HiperTURB is to improve the weldability and castability of high temperature capable superalloy castings. The expected impact will be linked to weight, manufacturing and maintenance cost reduction of TRF components. This objective will be achieved due to a combination of innovative chemistry adjustments, tailored casting solidification strategies, specific heat treatment and innovative welding techniques to control grain size, phases formation, segregation and residual stresses. Two new superalloy castings with enhanced weldability will be developed. At casting level mould design to control cooling gradient together with the use of inoculants, chillers and shell design will allow to tailor casting solidification. Heat treatment stage will be adjusted in terms of pre and post welding operation sequence (HIP + solution annealing), processing parameters and the introduction of cryogenic heat treatment. Weldability assessment of two new alloy castings will be assessed by standard hot cracking tests and simulated repair and structural welds on simple parts and real geometry-like components. Both TIG and laser based welding processes will be investigated. Development process will be supported by advanced simulation techniques based on Thermocalc, Dictra, Procast that will enable a more precise approach on final alloy microstructural and castability results. The castability of the alloys will be validated by the design of specific test samples that will be checked to detect casting defects such as shrinkage, hot tearing sensitivity.... Evaluation of internal and external defects will be carried out by non-destructive tests. Mechanical properties of alloys under development such as creep and tensile test at low and high temperature will be performed. Component like geometry cast parts will be manufactured at the end of the project, testing their final properties in terms of castability and weldability.

The main objective of the project is to develop a Smart solution for connecting process and material characteristics to achieve a new generation of digital materials in the automotive industry demonstrated by developing a new brake system with an anchor at least 12.5 % lighter and a housing with 10% improved machinability. The new developed solution will reach in next five years to the 35% of the European iron foundry market, 10% of the Worldwide level iron foundry market. A new smart data management module “DigiMAT module” will be developed by one SME specialized in ICT solutions. Its development will be supported by a sensor network and an advanced data management system already running in the iron foundry company. This smart module will consist on a specific algorithm for each digital material development combined with an automatic protocol definitions system that will conform a specific methodology. It will acquire, store, process and analyze data coming from a previously defined set of trials. . Its validation will be completed with the homologation of new digital materials by the TIER 1 company and by their introduction in the foundry company portfolio. In parallel the TIER 1 company will develop a lighter anchor based on the developed high yield material. This lighter anchor integrated into a new brake system will be functionally homologated by the TIER 1 and final user (OEM). Finally, partners will commonly develop a business plan for quick take up of the project results. Digital materials can have a wide impact in industry and society. First stage will report significant business opportunities to ICT companies and increase turnover of Tier 1 in the brake area of the automotive sector(+30%). The potential application to all type of material can render in significant global weight reduction in transport media and more sustainable development of industrial processes.

The overall aim of the “Rib-On” project is to develop and manufacture an innovative stamping die based on a modular/reconfigurable and low cost approach to successfully produce different outer external wing rib models using new high performance aluminium alloys and tailored die steel and coating solutions. The die will serve to manufacture different shape/length aluminium ribs. The following challenges must be overcome for the success of the project: -Hot forming of aluminium is not a widespread technology -Die users allow little play to improvement by material selection. -Modular/reconfigurable dies are infrequent. -Integrating heat treatment and stamping in a single operation allows reducing costs but is difficult to achieve. These five points lead to the most remarkable fields of expertise that gather at Rib-ON project. The consortium has wide experience in relation to the expected impacts. BATZ is a stamping die manufacturer for automotive and engine part manufacturer for aerospace industries and IK4-AZTERLAN / F.AZTERLAN has an extensive experience of more than 30 years in metallurgy. As for the operative approach, Rib-ON proposes to face the development of the new aluminium wing rib hot stamping die in the following sequence: 1.Functional requirements of the die will be set at first (WP1). 2.Once the die requirements are set, its concept design will be developed (WP2): 2.1.Processing window of the aluminium sheet must be defined. 2.2.Selection of the most advantageous die steel and coating will be performed. 2.3.Shapes of the blank and the forming surface of the die will be designed for each wing rib by simulation. Die cooling channel design will be simultaneous. 2.4.Modular die concept will be developed and prepared for subsequent detailed design. 3.Detailed design of the die and the corresponding manufacturing plan will be carried out (WP3&4) 4.The die will be set at BATZ's facilities for validation (WP5)