Simulation and Process Optimization of Powder Filling and Vibration Densification in Hot Isostatic Pressing for Turbine Disk Structure

The initial packing state of powders during the hot isostatic pressing directly affects the densification behavior and component forming accuracy. Based on the discrete element method (DEM), a powder filling and vibration model for a typical turbine disk structure is established, and its reliability verified through experiments.The effects of powder particle size, filling conditions (vibration frequency, amplitude, and direction), and capsule geometric parameters (blade angle and thickness of the turbine disc) on the packing density and distribution characteristics of powders are systematically analyzed. The results demonstrate that the discrete element model can accurately reproduce the powder filling and vibration process, with the error of the repose angle controlled within 0°-4°, confirming its applicability. The simulations indicate that the optimal packing density and uniformity are achieved when the vibration frequency is 30 Hz and the amplitude is 1 mm, with an average packing density of 0.635. Vertical vibration is found to promote overall uniform distribution, whereas horizontal vibration results in higher local density. An increased particle size ratio improves the average packing density but intensifies segregation. A larger blade inclination angle leads to insufficient packing, while an increased blade thickness mitigates the wall effect and enhances the overall packing quality. This study reveals the key mechanisms during the vibratory filling process and provides insights into the powder flow and interaction processes at the particle scale, offering valuable support for optimizing the powder HIP filling process.