Simulation and verification of near-net shaping a complex-shaped turbine disc by hot isostatic pressing process

A new constitutive relation for powder materials used in finite element analysis (FEA) of hot isostatic pressing (HIP) complex-shaped parts was derived from Perzyna’s elastic-viscoplasticity equations, and the stick–slip boundary modelling and thermomechanical coupling solution were achieved. The temperature-dependent mechanical and thermal parameters were determined through experiments. A complex-shaped turbine disc from Inconel 625 alloy has been simulated and produced. The predicted dimensions and relative densities have been compared with those measured from the experiments, which shows a good agreement for most regions of the turbine disc. The reasons for local predicted discrepancies and physical defects were discussed, and future improvements for FEA simulation and HIP process were outlined.