Simulation-based Manufacturing of Complex Shaped Near-net-shape Components by Hot Isostatic Pressing with Integrated Rapid Cooling

Following the development of hot isostatic pressing (HIP) with integrated rapid cooling technology, it is now possible to combine the consolidation of encapsulated powder and subsequent heat treatment in a single step. Therefore, a simulation method combining discrete element (DE-) and finite element (FE-) simulations was developed to predict both the deformation and the microstructure in HIP with integrated heat treatment. For HIP, both types of simulations were performed in the first step to predict the initial powder filling density distribution prior to HIP and the final capsule shape of the components after HIP. The FE-simulation was also used for capsule design to achieve near-net-shape production of complex shaped components. Additionally, the FE-simulation was applied to foresee the microstructural evolution during the cooling stage. The agreement between the experimental and simulated results validated the method is able to digitalize the manufacturing route and reduce the development time in industrial applications.