Manufacturing Process Selection for Aerospace Gas turbine blades & vanes

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1 for Aerospace Gas turbine blades & vanes Temperature- Pressure Cross Section of a Gas Turbine (P-T Distribution) Vane / Blade Materials : Super Alloys like CM 247, RENE 80 Disc / Casing Materials : Udimet 720, INCO 718, Powder metallurgy discs Coatings: Platinum Aluminide Thermal Barrier Coatings Take - off Air work Climb Bomb Combat 50 Ferry 25 0 Loading Spectrum Time - Minute ( Approximate) Evasion Touch and go Sections Showing Internal Cooling Channels Produced by Ceramic Cores Complex environment & Loads 1. Centrifugal 2. Thermal 3. Steady 4. Vibration 5. Fatigue 6. Fluctuating pressure fields 7. Creep 8. Mechanical stress -80% UTS,

2 Process Requirements for the Gas turbine blades Function: Gas Turbine Blade -Power Extraction Constraints : Material: Ni Based Super Alloy Shape: 3D hollow Mass: kg Minimum section: 1.5 mm Tolerance: < ± 0.1 mm Surface roughness: < 2.0 μm Batch size: 1000 Technical constraints Quality constraints Economic constraints Objective: Free variables: Minimize cost Choice of Manufacturing process

3 Component Material Mass of Component

4 Tolerance Minimum Section Thickness

5 Roughness Economic Batch Size

6 Shape of Component

7 Present Manufacturing Processes Casting Processes: Equiaxed investment Castings- CM 247 LC, Rene 80 Directionally Solidifed castings- CM 247 LC, Rene 80 Ceramic cores : CIM Forging Processes: HIP for Porosity Removal Hub : Forged Manufacturing Processes: Turning, milling, drilling, boring Grinding, EDG, EDM, Wirecut Creep feed grinding, Broaching Tube drawing, tube bending EDM / Laser drilling of film cooling holes Shot Peening- disc holes & firtree Tumbling- Surface finish Coating process: Bond Coat Thermal Barrier Coating Creep feed grinding EDM / Laser drilling

8 Alternate Manufacturing Processes Dual Property HIP Rotor LP Turbine Integral Rotor CONCLUSION: Gas Turbine Blade and Vane components are produced through investment casting process using Ni based super alloys. The operating temperature range of these components is very close to the melting point of these alloys. In order to withstand these high thermal gradients, the blades and vanes are made hollow, using ceramic cores during investment casting process, with complicated aerofoil shapes and very thin wall thicknesses, through which compressed cooling air is circulated. These ceramic cores have fine features such as tie pin holes, turbulators and channel wall cross-overs which generate the hollow cavity of turbine blade and vanes.

9 REFERENCES 1. Sarojrani Pattnaik, D. Benny Karunakar, P.K. Jha,; Developments in investment casting process A review, Journal of Materials Processing Technology 212 (2012) G. Appa Rao, M. Sankaranarayana, and S. Balasubramaniam, Hot Isostatic Pressing Technology for Defence and Space Applications, Defence Science Journal, Vol. 62, No. 1, January 2012, pp Pradyumna R,Sridhar S, A Satyanarayana, Alok Singh Chauhan and Baig M A H, Wax Patterns for Integrally Cast Rotors/Stators of Aeroengine Gas Turbines, Materials Today: Proceedings 2 ( 2015 ) Pradyumna R, Satyanarayana A, Alok Singh Chauhan, and Baig M A H, Tooling for Ceramic Cores of Dual Property HIP Rotors, International Colloquium on Materials, Manufacturing and Metrology, August 8-9, 2014, pp Vijayakumar M., Process Technology for making Sintered Ceramic Cores, Metals Materials and Processes, 2007, Vol 19, No. 1-2, pp The Jet Engine, The Technical Publication department,rolls-royce plc, 5th edition (1996), ISBN

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