The project is structured into several key activities, each designed to advance the development of innovative hot forming technology. The journey begins with identifying a suitable demonstrator geometry and selecting components of commercial interest. The appropriate sheet alloy, tolerance requirements, and possible process parameters will be determined. Next step, will explore potential non-metallic tooling materials, narrowing down to two ceramic variants for evaluation. The design of test specimens and demo tools will also take place. Another activity focuses on creating an induction coil solution tailored to the demo tool, ensuring effective direct heating of non-magnetic aerospace materials. When these steps are finished it’s time for the experimental activities, where specimen geometries of the ceramic tool material are tested and evaluated of compression performance under conditions relevant to commercial hot forming. Next phase involves manufacturing of the demo tools and carrying out induction heating and hot forming tests. The heat distribution will be evaluated, assess the impact on tooling materials, and analyzing shape deviations for the demonstrator geometry, focusing on the two selected material solutions. One activity will focus on assessing the sustainability gains and any potential drawbacks compared to current hot forming methods. This includes detailing how the new tooling concept can contribute to net-zero production in a realistic scenario. This comprehensive approach ensures that each aspect of the project is meticulously managed and contributes to groundbreaking advancements in hot forming technology.

The thesis work will focus on calibrating material parameters in a stress relaxation model based on performing hot tensile tests. This model can be used to predict the springback in the hot forming process by performing a FE-simulation. The student will also be involved in other activites connected to the project.
If interested contact Martin