Near net-shape manufacturing costs

Abstract

Improved efficiency in aero engines requires leaner fuel burn, resulting in higher working temperatures and the use of high temperature alloys. These high temperature alloys are extremely expensive and it is widely known that their material costs contribute to a significant fraction of the total product cost. Near net-shape manufacturing techniques such as Hot Isostatic Pressing, (HIP) provide a way of reducing material costs through a high buy-to-fly ratio, compared to traditional manufacturing routes. Cost modelling of some existing components and processes within Rolls-Royce Plc uses a parametric approach, using historical data of similar components and processes to establish cost estimates. The parametric approach is unsuitable for preliminary costing of novel components and processes, where historical data is no longer relevant or there is little production data available. An object oriented parametric cost model, with discrete event simulation, will remove the reliance of historical data and allow preliminary design of novel components and processes to be conducted. Part of the Resource Efficient Manufacture of high performance hybrid Aerospace Components (REMAC) project is to manufacture a high performance Nickel-based alloy component via net-shape powder HIPing and complete a cost, energy and environmental assessment. © copyright 2008 Rolls-Royce plc. © 2008 Springer-Verlag London Limited.