Case study “Utilisation of Process Simulation & Multi-laser Powder Bed Fusion to Produce a Turbine Exhaust Casing ‘H-Sector’"

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Combining the capabilities of the MetalFAB1 with process simulation to create large Aerospace components right first time

GKN Aerospace, Ansys and Additive Industries have collaborated to demonstrate their shared capabilities in the production of a large aero engine component. The H-Sector – a Notional Application supporting technology development targeted for future series applications on engine platforms - is part of the Turbine Exhaust Casing assembly within a turbofan engine and has been identified as a candidate with a potential business case for AM production. Such a component helps GKN Aerospace to establish AM capabilities across the manufacturing value chain, aligned to future engine requirements. To meet the requirements of GKN Aerospace in terms of quality and accuracy full scan field multi-laser powder bed fusion from the Additive Industries large frame MetalFAB1 system, and advanced AM process simulation and geometry compensation tools from Ansys have been assessed in this collaboration.

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