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Rapid prototyping in manufacturing of core models of aircraft engine blades

Article  in  Aircraft Engineering and Aerospace Technology · July 2014

DOI: 10.1108/AEAT-10-2012-0192

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 Rapid prototyping in manufacturing of core
models of aircraft engine blades
Paweł Rokicki, Grzegorz Budzik, Krzysztof Kubiak, Jacek Bernaczek, Tomasz Dziubek,
Marek Magniszewski, Andrzej Nowotnik and Jan Sieniawski
Rzeszow University of Technology, The Faculty of Mechanical Engineering and Aeronautic, Rzeszów, Poland
Hubert Matysiak
Research Center “Functional Materials”, Warsaw University of Technology, Warszawa, Poland
Rafał Cygan and Andrzej Trojan
WSK “PZL-Rzeszów” S.A., Rzeszów, Poland

Abstract
Purpose – The purpose of this paper is to present the advantages of computer-aided design/rapid prototyping (CAD/RP) usage in designing and
manufacturing of the core models used for precise casting with direct and single solidification of aircraft engine turbine blade cores.
Design/methodology/approach – The process of modelling three-dimensional CAD geometry of research blade in relation to the model of the core
was presented with different wax types used in the RP technique.
Findings – The geometry of the blade model has been designed in a way which allows making a silicon mould on the basis of a base prototype
in the process of rapid tooling (RP/RT). Filing by different wax types was investigated in mean of the impact on filling accuracy of the mould cavity.
Originality/value – The resulting models were used to make ceramic moulds and carry further work on the development of casting technology in
the process of directional solidification and single crystal solidification of core blades of aircraft engines.
Keywords Engine blades, Precise casting, Rapid prototyping, Directional solidification, Rapid tooling
Paper type Research paper

Introduction ● removal of mould and core; and

The increase in the aircraft engine performance is associated
with temperature increases of the turbine. Some of the limits
for rising the temperature of the turbine components are the
material parameters of the hot engine (Onyszko et al., 2010,
Szeliga et al., 2009, Hu et al., 2011, Lin et al., 2011). It is
possible to use cooled turbine blades by means of internal
cooling channels. Preparation of this type of blades in the
process of precision casting requires special models with inner
cores (Figure 1). The process comprises the following steps:
● computer-aided design (CAD) modelling;
● processing of the STereoLithography (STL) format;
● stereolithography (SLA) model preparation;
● model kit manufacturing;
● silicon mould manufacturing;
● cutting of the silicone mould;
● insertion of the core and making wax model;
● drawing wax model;
● execution of a shell mould;
● removing wax model from the mould;
● performance cast;
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● casting finishing (Figure 1).
The manufacturing of the blades of aircraft engines (Budzik,
2007, Sieniawski, 1995) can be realized with the application
methods of rapid prototyping/rapid tooling (RP/RT) on chosen
stages of technological process (Budzik, 2007, Liu, 2008).
The RP of blades casting models is based on
three-dimensional (3D) models manufactured in 3D-CAD
systems which have the surficial and lump modelling options.
It is necessary to transform data describing 3D digital model in
the software way to make it readable by the systems of RP (e.g.
STL format). Software of the RP devices TRANSFORMS
3D-RP model to a set of layers from which the physical
prototype is being produced (Budzik, 2007, Budzik et al.,
2004, Budzik et al., 2006, Budzik, 2013).
The article presents main stages of RP/RT process of model
kits elements for manufacturing ceramic moulds which are
applied for single crystal blades of engines production. The
additive RP method – Jetting System (PolyJet method) – has
been applied for production of base prototypes (so-called
masters). These masters can be manufactured by means of RT
models with the vacuum casting (VC) technology assist (Budzik,
2013, Gajdos and Slota, 2013). This process concerns the
manufacturing of tools (matrices or silicone moulds) and also
prototypes under lowered pressure in the vacuum chamber.

Financial support of Structural Funds in the Operational Programme -

Aircraft Engineering and Aerospace Technology: An International Journal
86/4 (2014) 323–327 Innovative Economy financed from the European Regional Development
© Emerald Group Publishing Limited [ISSN 1748-8842] Fund – Project “Modern material technologies in aerospace industry”, No
[DOI 10.1108/AEAT-10-2012-0192] POIG.0101.02-00-015/08, is gratefully acknowledged.

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 Rapid prototyping in core models of aircraft engine blades
Paweł Rokicki et al.
Figure 1 A schema of the application of RP techniques for precision
casting core models using an RP/RT process
Tools of this type allow the manufacturing of wax casting models
(Budzik, 2009, Cygnar and Budzik, 2005).
Core blade 3D-CAD and 3D-STL models
Modelling of aircraft engine turbine’s blades needs application
of 3D-CAD systems which have the possibilities of surficial
and lump modelling (CATIA, UGS-NX, ProE, SolidEdge
etc.). The complex shape of blade’s plume can be exactly
reproduced with application of surficial modelling method.
Manufacturing of physical prototype and export of the data to
RP device format need transformation of a surficial model into
a geometrical one (Budzik and Sobolak, 2006). The 3D-CAD
and 3D-STL models of aircraft engines core blade are
presented in Figure 2.
Casting models in RP/RT process manufacturing
Jetting System with OBJET PolyJet technology is a layer RP
method. Above all, the most important advantages of the
method are: precision in model creation, possibility of
Figure 2 The 3D-CAD and 3D-STL prototype of core blade models
Figure 3 (a) 3D printing PolyJet process, (b) prototype of blade model
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Aircraft Engineering and Aerospace Technology: An International Journal
Volume 86 · Number 4 · 2014 · 323–327
Figure 4 Degassing of the silicone (a) pouring into the container with
model kit (b)
complex internal and external structure production and large
reproducibility. For this and other reasons, manufacturing of
precise elements like blades of aircraft engines is possible using
Objet Eden 260 machine by PolyJet (Budzik, 2007).
Manufacturing of PolyJet model is based on liquid
polymerization of (photo-hardenable) resin with use of
ultraviolet lamp in layered process. Figure 3 presents 3D
printing PolyJet process (Figure 3a) and prototypes of blade
model (Figure 3b).
RP of blades casting models in silicone moulds belongs to
indirect RP methods relying on application of RT technique,
i.e. silicone mould in VC technology. Manufacturing of
silicone mould contains the following stages:
● preparation of the model pattern (e.g. JS, SLA, FDM);
● manufacturing of mould’s construction and model system;
● preparation of mould and silicon pouring;
● thermal processing; and
● gashing of the mould and removal of model system
(Budzik, 2007).
Figure 5 Silicone mould annealing (a) and pouring with the modelling
wax (b)
Figure 6 Cored blades wax models made of different waxes: (a) Blue
Wax RECLM⫹, (b) A7FR/60, (c) KC4017B, (d) KC2690FDR, (e) B405, (f)
RECLM
 Rapid prototyping in core models of aircraft engine blades Aircraft Engineering and Aerospace Technology: An International Journal
Paweł Rokicki et al. Volume 86 · Number 4 · 2014 · 323–327

Table I. Properties and applications of modeling waxes

Wax designation Wax melting Mould temperature Mould annealing Mould fulfillment
Application Wax color (type) temperature, °C before pouring, °C time, h [air gaps per cm3]
Model kit Red B405 130 85 2 1
Model kit Brown RECLM 130 85 2 2
Model kit Grey-blue Blue Wax RECLM⫹ 130 85 2 2
Blades Light-green A7FR/60 140 90 2 5
Blades Dark-green KC4017B 140 90 2 3
Model kit, models Dark-red KC2690FDR 130 85 2 2

Figure 7 Geometrical deviation maps for different wax types: (a) KC4017B; (b) A7FR/60; (c) B405; (d) Blue Wax RECLM⫹; (e) KC2690FDR; (f) RECLM

325
 Rapid prototyping in core models of aircraft engine blades
Paweł Rokicki et al.
Silicone mould allows manufacturing of casting models by
casted waxes. Figure 4 shows degassing of MM240TV silicone
mixed with hardener in a vacuum chamber UGH400 (Figure
4a) and the silicone pouring into the container with model kit
obtained by PolyJet method (Figure 4b). Figure 5 presents
silicone mould annealing process (Figure 5a) and pouring of
the modelling wax (Figure 5b).
The possibility of applying different modelling
waxes in RP process
Waxes used for the manufacturing of kit models feature
different physical and functional characteristics. They mainly
Figure 8 Blade test casting
Figure 9 ALD VIC furnace for investment casting (a), preparation of the model kit (b)
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Volume 86 · Number 4 · 2014 · 323–327
refer to processing shrinkage and the ability to fill up the
mould. The objective is to minimize shrinkage of the wax in
blades manufacturing process. For the rest of the model, kit
shrinkage has a negligible meaning. In the mass production,
blades models are produced by injection into metal matrix.
Waxes are adapted to the processing properties of the injection
process. However, there is no description of the processes and
waxes characteristics in the context of their use in
implementation of the silicon mould models or dies for cored
blades sets production. In this case, the process of filling the
matrix is affected by the presence of a core. The core as well
as the material from which it is made can cause disruption in
the mould filling process by the wax, i.e. re-gassing during
solidification of wax. In the paper, results of mould filling by
different wax types through manufacturing of blades cored
models are presented (Figure 6, Table I). Additionally, results
concerning temperature and time of mould annealing before
pouring and wax melting temperature have been described.
Based on the observations, it can be concluded that waxes
B405, RECLM, Blue Wax and KC2690FDR have similar
processing characteristics. These waxes are often used for
manufacturing of auxiliary elements of the models. However,
4W-Jz and KC4017B composite waxes are suitable for
performing the injection waxing blades; they can be also used
in the rapid manufacturing process.
Geometry variation measurement of models manufactured
from different wax types has been performed and included in
the study. The aim of the study was to compare wax-type
impact on geometrical accuracy of the models. Figure 7
presents geometrical deviation maps for all the wax types. The
differences are particularly noticeable between the group of
waxes for the model sets manufacturing (KC2690FDR,
RECLM, Blue Wax RECLM ⫹, B405) and composite waxes
 Rapid prototyping in core models of aircraft engine blades
Paweł Rokicki et al.
to produce casting models, in which to the wax a filler is added
having a reduced shrinkage processing (A7FR/60, KC4017B).
Additionally, in the pictures, cored blades drawn in and
around the wax core can be observed (lesser in case of
composite waxes).
Presented wax models allowed manufacturing of blades test
castings by direct solidification method (Witek et al., 2010,
Wieczorowski et al., 2010). Figure 8 presents cored blade of
aircraft engine with a single crystal structure. The blade was
cast in ALD vacuum investment casting (VIC) furnace.
Solidification front was processed in a way allowing single
crystal growth (Piccione et al., 2013). Figure 9 presents the
furnace and the wax model kit prepared by the RP/RT method
described in the paper. The accuracy of the casting geometry
is comparable with the injection technique conventionally
used in the industrial scale. All the geometrical parameters
fulfill the standards and norms of industrial requirements.
Conclusions
Technologies of RP enable manufacturing of model kits
elements for cored ceramic casting moulds. Prototypes of
model kit elements were produced by means of PolyJet
method that required application of special ceramic
construction for casting mould as well as special process of
models removal. It is possible to prevent this as a result of RP
indirect method application based on rapid manufacturing of
tools (silicone matrices), in which wax casting models are
manufactured.
Application of RP, RT and rapid manufacturing method
combination allows achievement of cored blade castings
models of aircraft engines and also remaining elements
of model kit. These methods also enable suitable way of
connecting model kit elements, what shortens a time of
preparation of moulds for single crystal casts of aircraft
engines blades. However, it needs to be noticed that the
majority of wax types used for models manufacturing are
processed in the injection method with metal matrix. For this
reason, processing of these waxes in the RP needs proper
selection of the process parameters, i.e. pouring temperature
or silicone mould cavity temperature. It has a major impact on
wax filling and thus on proper performance of casting and
aircraft engine cored blade models.
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Corresponding author
Paweł Rokicki can be contacted at: prokicki@prz.edu.pl