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Manufacture of Aircraft Turbine Blades

Manufacture of Aircraft Turbine Blades

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how aircraft turbine blades are manufactured..
how aircraft turbine blades are manufactured..

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Published by: RACHANASAXENA11013978 on Oct 01, 2009
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07/27/2013

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Seminar Report on

Manufacture of Aircraft Turbine Blades

Submitted by deepaksubudhi456@gmail.co

Propeller versus Jet Propulsion

ENGINE MATERIALS .

Material strength .

How does a gas turbine work ? “Newton’s 3rd Law” .

Jet Engine Layout .

Blades • • • • • • • • Compressor blades : Sucks in air from atmosphere Turbine blades : Rotates due to combustion of fuel in combustion chamber Various stages: HPTR (casting) LPTR (forging) 1st nozzle vane (casting) 2nd nozzle vane (casting) Stator blades (forging) .

Turbine blades in a jet engine experience: • • • • • • • Mechanical forces • Creep • Fatigue • Thermo-Mechanical fatigue High temperature environment Oxidation Hot corrosion .

Ni-based superalloys are used for manufacturing Turbine Blades .

Process Chart • • • • • • • • • • • • • BILLET CHART VISUAL INSPECTION PLUGGING OF INT. GRINDING TRANSFERING OF MARKS GRINDING GRINDING GRINDING BENCH WORK INSPECTION • • • • • • • • • • • • • MILLING BENCH WORK BENCH WORK POLISHING ZYGLO INSPECTION BUFFING BLOWING INT.INSPECTION CUTTING OF SPECIMEN SET MAKING PLUGGING OF INT.CAVVITY INSPECTION ALITIZING .CAVITY GRINDING GRINDING TRANSFERING OF MELT NO.

• • • • • • • • • • • • • INSPECTION ULTRASONIC WASHING INSPECTION DIFFUSION ANNEALING INSPECTION REMOVAL OF PLUG STRIPS PLUGGING OF CAVITY GRINDING GRINDING BENCH WORK ROUGH MILLING FINAL MILLING BENCH WORK • • • • • • VISUAL INSPECTION GRINDING GRINDING GRINDING MILLING MILLING .

Investment Casting Investment Flask Casting Procedure .

Investment Shell Casting Procedure .

casting processes and thermal barrier coatings .Important points on Blades • A higher efficiency turbine results in lower fuel consumption • This can be achieved by Higher turbine inlet temperature • A more efficient air-cooling of turbine blades accounts for half of increase in efficiency while the other half has been brought about by improved super alloys.

• Serpentine cores and multi-shaped-hole film cooling enables high pressure turbine blades and vanes to operate with TET well above the melting point of super-alloys (nearly1570°C) • Earlier Equiaxed castings were used which are now a days replaced by Directionally Solidified castings .

Directional Solidification Process • First pioneered by Pratt and Whitney and VIAM. Russia • It is accomplished by Investment Casting Process • It aims at producing elongated grains aligned parallel to the thermal gradient .

Directional Solidification Process .

This is due to a thermal gradient created between upper portion of ceramic shell and chill plate • After start of solidification. chill plate is lowered • The initial columnar grain structure.Procedure • Carried out by investment casting : Pouring of molten alloy into a pre-heated ceramic shell mould which is open at bottom and sits on a water-cooled copper chill plate • Thin layer of equiaxed grains are formed • Subsequent growth favours those grains parallel to the thermal gradient and produces columnar array of grains. proceeds to fill the entire mould cavity resulting in “Directional Grain Structure” .

Heat Treatment of DS Blades Three types of heat treatment are provided: • A solution heat treatment in order to increase alloy strength • Coating heat treatment to bond the coating • An aging heat treatment to precipitate carbides and borides at the grain boundaries .

mechanical properties. hot corrosion resistance and phase stability .Single Crystal Solidification Process • It is an extension of eliminating grain boundaries in DS technology by removing grain boundaries and have a SINGLE CRYSTAL • Nickel based super alloys with higher concentrations of Rhenium and Tantalum are used • Platinum group of metals can be used which will enhance liquidus.

Single Crystal Solidification Process .

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Further steps carried out   • • • • Forging Machining Profile grinding Profile cutting Root cutting Hand grinding    • • Sand blasting Coating Inspection Ultrasonic Testing Vibration Fatigue Testing .

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