SMS group supplies high-tech isothermal forging module to IFUM at Leibniz University Hannover

• Isothermal forging enables high-performance materials to be formed under vacuum, thus preventing the oxidation of these reactive materials
• Target applications: Development of new materials for components in the aerospace and medical technology sectors as well as for demanding industrial applications
• Enhanced research capacity for superalloys and accelerated technology transfer to industry
• Flexible module integration with fully automated sequence and robot handling

SMS group is to supply a state-of-the-art isothermal forging module to the Institute of Forming Technology and Machines (IFUM) at Leibniz University Hannover. This flexible and mobile vacuum module will be integrated into the existing synchronous screw press and implemented as part of the “High-performance materials of the future – HoWZu” research project, which is funded by the European Union’s EFRE infrastructure program and by the state of Lower Saxony.

The aim of the project is the development of new, scalable methods for the technological processing of innovative high-performance materials, which up to now could not be formed under conventional conditions. The mobile system is designed such that it can be flexibly integrated into the existing synchronous screw press with a maximum press force of 6,000 kilonewtons and be dismantled again, if required. The isothermal forging module at the Hanover site is scheduled to go into operation at the end of 2026.

“We chose SMS group as our supplier and partner: We were impressed by its proven expertise in vacuum technologies for secondary metallurgy and profound understanding of metallurgy. With our new isothermal forging module, we are driving the evolution of novel superalloys and setting new standards in isothermal forming,” says Julius Peddinghaus, Bulk Metal Forming Team Leader at IFUM.

Isothermal forging is a highly specialized forming process that is used in particular for reactive high-temperature materials, such as titanium and nickel-based alloys. The distinctive feature of this process is the combination of constant temperature, vacuum or inert gas conditions, and the controlled material behavior during hot forming. This prevents unwanted chemical reactions and provides for a uniform microstructure.

Inside the module, a batch consisting of a maximum of ten powder-pre-pressed blanks is processed fully automatically. The blanks made of superalloys – for example titanium and nickel-based alloys – are placed in the loading chamber of the isothermal forging module. After closing, the air is pumped out of the chamber to a pressure of approximately 0.012 mbar, creating a vacuum to prevent reactions with oxygen. The workpiece and the pressing tool inside the module are then heated to around 1,100 degrees Celsius. The identical temperature of both tool and workpiece prevents any undesired changes in the microstructure during the forming process. A robot operating in a vacuum removes the heated workpiece from the furnace and places it precisely into the die. The deformation process takes place under isothermal conditions, at a very slow rate of deformation. After forming, the robot removes the component and places it in the extraction chamber. The chamber is opened and the finished components are removed only after all parts from the inserted batch have been formed.

“Our close cooperation with IFUM in research and teaching has fostered a trusting partnership. We are proud that our new development has impressed all concerned and look forward to continuing this successful collaboration,” says Axel Rossbach, technology expert at SMS group.

With this investment, IFUM will benefit from a powerful research tool that will significantly advance the development of new materials for the most demanding applications in aerospace, medical technology, and industry.