A new two-layer process based on hot forming and diffusion bonding for forming a hollow titanium wide-chord fan blade with complex geometries was developed. An essential approach for optimal blank design was proposed. The present process employed a more reliable and controllable method to construct the internal ribbons, instead of complicated superplastic forming. To evaluate the practicability, a numerical method was used to investigate the thickness uniformity, structural integrity and skin defects of forming results using ABAQUS. A series of experiments were conducted to validate the simulation results. The Ti-6 Al-4 V alloy was adopted as the forming material, and blanks optimized by the proposed approach were used. The results show that a scaled-down version of the hollow wide-chord fan blade without defects is successfully formed. In addition, it is observed that the experimentation and simulation agree well.
Rare Metal Materials and Engineering
Science and Technology Support Program of Jiangsu Province (BE2013123).
hollow wide-chord fan blade
optimal blank design
finite element simulation