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Investment Casting of Gas Turbine Blade by Used of Rapid Technologies

Article in AUSTRALIAN JOURNAL OF BASIC AND APPLIED SCIENCES · July 2009

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Australian Journal of Basic and Applied Sciences, 3(3): 2979-2988, 2009
ISSN 1991-8178
© 2009, INSInet Publication

Investment Casting of Gas Turbine Blade by Used of Rapid Technologies

D. Safaeian, M. Vaezi

Department of Mechanical Engineering, Babol University of Technology, P.O. Box 484, Babol,
Iran

Abstract: This study has investigated the ability of two different rapid technologies, namely, MultiJet Modeling
(MJM) and silicone rubber molding to manufacture investment casting pattern of gas turbine blade. For this
reason, the second stage blade of Rus ton TA 1750 (1.3MW) gas turbine was digitized using CMM and then its
wax pattern manufactured by MJM technology and silicone rubber molding technique. Regarding the inspection
results of manufactured patterns, maximum deviation of MJM pattern was -0.111mm. While for pattern fabricated
using silicone rubber molding, maximum deviation was +0.298 mm. Considering results of this experimental
research, both techniques are usable to manufacture expendable pattern of gas turbine blade but in terms of part
accuracy, silicone rubber molding is not successful approach for manufacturing of blade expendable patterns.
MJM technology enjoys more dimensional accuracy as well as more ability compare with silicone rubber molding
technique.

Key words: Rapid prototyping, Gas turbine blade, Investment casting, Wax pattern, MultiJet Modeling, Silicone
rubber molding.

INTRODUCTION

Gas turbine blades are as complex industrial parts due to their material, narrow dimensional tolerances and complicated
freeform surfaces. In gas turbines, compressor and turbine blades play vital roles and one or a series of blades transfer
energy through dynamical function. The function of any industrial turbine directly relates to angular movement changes of
fluid while passing through a row of blades. As the surface of blades is comprised from freeform surfaces, they accounted
as complex industrial parts. At present, there are used processes such as forging, investment casting, machining and single
crystal growth for manufacturing of the blades but any of these methods are time cons uming and expensive especially in
R&D, optimization and prototyping steps and have some limitations. Specially, in the phase of R&D while turbine blades
with complex internal cooling channels are considered, even Computer Numerical Control (CNC) machines having 4 or 5
simultaneous axis have such complications. Hence, manufacturing these parts required another approaches like rapid
prototyping technologies.
The term rapid prototyping (RP) refers to a class of technologies that are used to produce physical objects layer-by-
layer directly from computer-aided design (CAD) data. The main virtue of RP systems is that they build prototypes in one
step, directly from the geometric model of the part to be manufactured (Raja, V. and K.J. Fernandes, 2007; Yao, A .W.L.,
2005). RP techniques are fast becoming standard tools in product design and manufacturing (Chua, C.K. and K.F. Leong,
1998). With revolutionary capabilities to rapidly fabricate three-dimensional parts for design verification or to serve as
functional prototypes and production tooling, RP is an indispensable tool for shortening product design and development
time cycles (Cheah, C.M., C.K. Chua, 2005; Onuh, S.O. and Y.Y. Yusuf, 1999). RP, which is a powerful communication
tool that bridges design, marketing, process planning and manufacturing, can facilitate the implementation of concurrent
engineering (Griffiths, M., 1993; Jacobs, P.F., 1996). Today, unique ability of RP/RM technologies for rapidly fabricate
parts having complex free-form surfaces, made considerable evolution in the process of manufacturing parts such as
impellers and gas turbine blades. Particularly, there can be s een increased attempts for rapid manufacturing of the
functional prototypes of gas turbine blades with internal cooling channel in titanium and nickel-based superalloys using
rapid manufacturing (RM) technologies such as Direct Metal Laser Sintering (DMLS), LaserCUSING and Selective Laser
Melting (SLM).

Corresponding Author: Davood Safaeian, Department of Mechanical Engineering, Babol Noshirvani University of
Technology, P.O.Box 484, Babol, Iran.
Email: d.safaeian@yahoo.com, Tel/Fax: +98(0)9125397151
The application of RP-fabricated patterns as substitutes for the traditional wax patterns employed in investment casting
stems from the fact that RP materials can be melted and burned out from the ceramic shell (ceramic shell casting) without
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damaging it. Most commercialized RP techniques are capable of producing such patterns that can be used directly in
investment casting. Most of the limitations encountered with earlier applications of RP-fabricated investment casting
patterns include damage to the ceramic shells due to excessive thermal expansion of the pattern or the release of corrosive
degradation by-products during pattern burn out, which cracks or attacks the cavity surface of the shell. Ceramic shell
cracking is attributed to a mismatch in the coefficient of thermal expans ion (CTE) between the RP and ceramic materials.
Most RP materials have CTE values that are larger than the ceramic material and as such, the expansion of the pattern
during heating imposes significant amounts of stress on the ceramic s hell. Shell cracking occurs when the stresses imposed
by the expanding pattern are greater than the modulus of rupture (M OR) of the shell material. In some cases, residual ash
can also cause defects in the final castings when present in relatively significant quantities. Also, due to the high operating
and material costs of RP techniques, the utilization of RP techniques has been reported to be beneficial only when five or
fewer castings are required. The application of RP techniques to produce sacrificial investment casting patterns can be
classified under two methods: the direct RP method, and the indirect RP method. The direct RP method covers the
application of RP techniques for producing plastic, wax or paper investment casting patterns for fabricating ceramic moulds
that can be employed directly for metal casting (i.e. direct shell production method). For the indirect RP method, alternative
molds produced via silicone rubber molding in conjunction with an RP-fabricated master pattern of the final desired casting
are employed for the injection of investment casting patterns from foundry wax. In addition to silicone rubber molds, molds
fabricated with RP techniques can be used to produce investment casting wax patterns.
For the direct RP method, the RP-fabricated pattern can only be used to produce a single casting. On the other hand, for
the indirect RP method, the silicone rubber mold or RP mold can generate multiple wax patterns to produce a number of
castings. However, due to the cost of RP materials as mentioned, silicone rubber molds are usually the preferred choice for
indirect RP methods.

2. Objective: Sever service conditions such as high temperature, high mechanical stres s , thermal fatigue and corrosive
gases etc., resulted in manufacturing gas turbine blades from superalloys. Nickel-bas ed s uperalloys such as IN718 and
IN738 generally applying for hot parts of turbine. Rotor blades are mainly produced by investment casting process
consisting of wax injection, ceramic coating, wax removal, metal casting and finishing with no further machining on their
airfoil. Investment casting is a precision casting process whereby wax patterns are converted into metal parts following a
multi-step process (Groover, M.P., 2001). Investment casting is a key technique among a range of modern metal casting
techniques that is capable of providing an economical means of mass producing shaped metal parts containing complex
features (e.g. thin walls, undercut contours and inacces s ible spaces) which can be difficult or impossible to create using
other fabrication methods. Despite the wide range of applications in many industries, the standard (conventional) investment
casting process practiced in modern foundries has its drawbacks. Expendable wax patterns usually produced by the injection
of liquid wax into a precision mold. The dimensional accuracy of wax injection step introduces a great influence on the final
blade dimension and thus on finishing proces s (Behravesh, A.H. and S.A.M. Rezavand, 2007). Depending on the
complexity of the patterns, the cost of these metal tools can be in the range of a few thousand to one hundred thousand
dollars and the time taken to produce the tools can be two to 16 weeks. When the number of castings required is small in
quantity, it is not economical in terms of both cost and lead-time to produce the metal tools.
Hence, when it is needed to manufacture only few gas turbine blades , regarding to the problems for wax injection
process and also high cos t of tooling, it is necessary to use another model making techniques such as precis ion wax CNC
machining. However in case of complex industrial parts like gas turbine blades, replacement of precision machined wax
with RP technologies, results in a saving in cost of tooling and the lead time. The focus of the work presented in this paper
is on the production of sacrificial investment casting patterns using the MultiJet M odeling (MJM) technique. In addition,
the indirect RP method for producing injected wax patterns via a silicone rubber mold is investigated and compared to the
direct RP method.

MATERIALS AND METHODS

The s econd s tage blade of Ruston TA1750 (1.3MW) gas turbine was selected to implement reverse engineering and
manufacturing of investment cas ting pattern using MJM technology and silicone rubber molding (Fig.1). This blade is
located in the turbine compressor section and it was in IN738 nickel-based super alloy, weighted to 56.6 gr.

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Fig. 1: The second stage blade of Ruston TA1750 gas turbine

3.1. Digitization:
Computerized digital manufacturing proces s s tarts from reverse engineering (RE) operation. The RE technique has
widely applied in all kinds of areas, such as manufacturing, medical applications, automotive and aeros pace industry,
fabrication, and design of arts, etc. RE refers to the process of creating a CAD model from a physical part or prototype.
Different methodologies of RE are used to produce a computer-aided design (CAD) model from the digitization of a given
object by using a coordinate measuring machine (CMM) (Chang, C.C., M.Y. Lee, 2006; Varady, T., R.R. Martin, 1997;
Yau, H.T., 1997; M otovalli, S., 1998). Digitizers can be divided into two types, the contact system and non-contact system.
The contact CMM can automatically generate digitized surface data from a physical model by means of a touch probe.
Another approach is by noncontact digitization of surfaces with optical technology, which are much more efficient in speed
and much less human labor is required.
To digitize blade airfoil surfaces, it was used touch probe CMM. It was of type Bridge Structure from Mitutoyo Co.,
Model FN1106 possessing the ability of CNC digitizing. To fix blade on the CMM table, it was used blade root and using V
block blade oriented, as illustrated in Fig. 2. Airfoil digitizing was done in six arbitrary sections any including 167 points.
Platform also digitized in seven sections. For attaining the root profile, it cut from the blade with wire cut and measured by
profile projector. Considering the results of CMM and Profile Projector, root profile obtained.

Fig. 2: Blade digitization by CMM

3.2. Surface Modeling:
After obtaining the blade point cloud data, surface modeling operation was done on it using POWER SHAPE Software.
For this reason, first it was created 2-D profiles of different sections using obtained point clouds and then blade airfoil
surface was made by lofting suitable surfaces through created 2-D profiles. Continuity of curvature and slope may be
accounted as necessary conditions to improve designing and making a s mooth surface. Thus, regarding to continuity

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between NURBS Curvatures being of second-order, it means both curvature and slope are continuous, hence to create 2-D
profiles of sections, it was used NURBS Curves.
Finally, after making the surfaces and controlling them, Surface model converted to Solid Model to manufacture with RP
machines. It should be mentioned that, before this step it is necessary to remove all Gaps made between surfaces during
surface building operation. Also due to required final finishing process (creep grinding) after investment casting process,
1.5mm grinding allowance in the root area of blade model designed (Fig. 3).

Fig. 3: Design of 1.5mm grinding allowance in the root area for final finishing operation

3.3. Investment Casting Pattern Fabrication Using MJM:

MultiJet modeling (MJM) technology uses multiple print heads to deposit droplets of material in successive, thin
layers. Two major MJM techniques can be distinguished:
ThermoJet™. A 96 element print head deposits droplets of wax. Wax models can also be used as master patterns for
investment casting.
InVision™. A print head jets two separate materials, an acrylic UV-curable photopolymer-based model material and a
wax-like material to produce support structures for the model (Raja, V. and K.J. Fernandes, 2007).
In this study, it was used ThermoJet Actua apparatus (a registrated trade mark of 3Dsystems Inc.), to manufacture two
wax patterns of blade. Build layer thickness was selected as 0.1mm. Fig. 4 indicates produced blade patterns.

3.4. Investment Casting Pattern Fabrication Using Silicone Rubber Molding:

Nowadays, owing to the globalization of consumer markets and the cons equent increase in the numbers of competitors
facing any individual manufacturer, it is becoming more important for manufacturers to be first into the market with their
products. With rapid tooling (RT), successful case studies have proved that it is possible to reduce the product development
time by at least half. RT is most suitable for pre-series production. This involves manufacturing the product in its final
material and by the intended manufacturing process, but in small numbers (about 500 pieces). Pre-series production is us
ually to test production equipment and tools and to test the market introduction of a product.

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Fig. 4: Blade patterns produced by ThermoJet 3D printer

A variety of tooling can currently be produced using different RP technologies. For the purpose of classification,
tooling is divided into hard or soft tooling and also direct or indirect tooling. Tooling for short manufacturing runs is often
known as soft tooling as these tools are often made from materials such as silicon rubber, epoxy resins, low-melting-point
alloys, or aluminum, which are easier to work with than tooling steels . Tooling for longer manufacturing runs is known as
hard tooling and is usually made of hard tooling steels. In direct tooling, the tool or the die is created directly by the RP
process. For example, in the case of injection molding, the core and cavity, together with the gating and ejection s ys tem,
are produced in the RP process.
In indirect tooling, only the master model is created using the RP technology. From this master model, a mold is made out a
material such as silicone rubber, epoxy resin, soft metal, or ceramic.

3.4.1. Fabrication of Master Model for Silicone Rubber Molding:

For the indirect RP approach, a master pattern of blade was employed. The master pattern was fabricated on the
Perfactory RP system. The Perfactory process builds 3D objects from liquid resin, like stereolithography (SL) process, but
using a projector rather than a laser. It’s a registrated trade mark of EnvisionTEC, Germany.
The voxel planes are sequentially projected into the liquid resin using a Digital Light Processing (DLP) projector. The light
cures the liquid based photopolymer, turning it into a s olid, and as each Voxel Matrix is projected one after the other, a
complete 3Dimensional part is created. The Digital Micromirror Device (DM D) has been developed by Texas Instruments
for high quality digital projection. It is in the heart of all DLP projectors and consists of around 1.5 million individual
mirrors (it has an array of mirrors1400×1050), each mounted on tiny hinges and can be individually controlled. Each mirror
is only of size 13 ìm. With a build speed of 10–15 seconds per layer the proces s is well suited to building parts quickly, but
the use of a single
DMD with a finite matrix of pixels limits the process to small parts if a fine resolution is maintained (Hopkinson, N., R.J.M.
Hague , 2006). Because of perfactory system enjoys DLP projector technology to build model, therefore, sometimes it
called DLP system.
In this research blade master model built on the Perfactory standard system using the PIC 100 resin. It provides highest
quality details without sacrificing on toughness and ease of handling. Fig. 5 shows built master model using perfactory
system.
For validation of manufactured DLP master model of s ilicone rubber mold, it inspected by CMM which has s upported
with power inspect software. Maximum deviation measured was +0.0776mm, located in distance of Z=60mm from the
bottom surface of the root. Fig. 6 indicates inspection results of Perfactory pattern in the section Z=60 mm.

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Fig. 5: Blade master model produced by Perfactory system

Fig. 6: Inspection result of Perfactory pattern for section Z=60 mm

3.4.2. Fabrication of Silicone Rubber Mold with Dlp-fabricated Master:

Silicone rubber molding is the simplest and oldest indirect rapid tooling technique. Using this technique, a model is
submerged in a bath of liquid silicone. When the silicone hardens, it is cut open and the model is removed. Reassembling
the silicone parts leaves a gap that has the exact shape of the original model. By filling this gap with a two-component resin
under vacuum, a reproduction can be created. Silicone molds can last for as many as 20 reproductions. Silicone rubber soft
tooling is also substantially less expensive than computer numerically controlled (CNC)-machined aluminum tools (Hilton,
P.D. and P.F. Jacobs, 2000). In this study, blade silicone rubber mold was built using master model manufactured by DLP
process; by that two blade wax patterns was made. Fig. 7 shows produced silicone rubber mold with a built blade wax
pattern.
Process conditions such as melt temperature and holding time play an important role in the accuracy of the wax
patterns produced by silicone rubber molding technique. Table (1) s hows s ilicone rubber molding condition.

Table 1: Process conditions used for silicone rubber molding

Molding pressure Holding time Melt temperature
150 KPa 7 min 60 ºC

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Fig. 7: Produced blade silicone rubber mold with a built wax pattern

RESULTS AND DISCUSSIONS

To evaluate and compare the dimensional deviations encountered by the produced patterns, they inspected using ATOS
structured-light 3D scanner of GOM GmbH, Germany. The generated scan data is matched against data of the CAD model
(obtained via digitization) and a colored plot showing the difference in dimensions of both data sets is obtained.
Dimensional analysis is fulfilled via Geomagic Qualify software (powerful software for reveres engineering applications).
The amounts of shrinkage and deviations encountered by the patterns can be studied and evaluated from available color
plots. Figs. 8 and 9 indicate inspection result of MJM pattern and pattern produced using s ilicone rubber mold in form of
color plot, respectively. Due to the results of inspection, MJM technology had higher dimensional accuracy comparing with
silicone rubber molding. M aximum deviation of built pattern by ThermoJet system was -0.111mm.While maximum
deviation of pattern produced using silicone rubber mold was +0.298mm.

Fig. 8: Deviation color plot of MJM pattern

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Fig. 9: Deviation plot of wax pattern made by silicone rubber molding

Inspection of two built patterns by ThermoJet apparatus and silicone rubber molding actually indicates that the ability
of MJM technology to fabricate investment casting pattern of complex parts with high accuracy such as gas turbine blade is
more than silicone rubber molding technique. Also it must be note that new generation of MJM technology (Invision
System) possesses higher dimensional accuracy and better surface quality than ThermoJet system. Anyway, regarding to the
nature of two techniques MJM (direct method) and silicone rubber molding (indirect method), it seems that MJM
technology has higher potential for manufacturing accurate parts with narrow dimensional tolerances and fine details
comparing with silicone rubber molding technique.
Cooling rate, pattern shape and its wall thickness play an important role in the accuracy of the wax patterns produced
using silicone rubber molding technique. In away, thinner wall thickness of pattern results in higher dimensional deviation
of wax pattern. A s s een in Fig. 9, the effect of mentioned parameter (wall thickness) on dimensional accuracy is more
evident for the blade’s upper area of shank, since it has lower wall thickness and is more free to s hrink with respect to the
lower area of shank which is attached to the root (that is considered as a constrain).
Lead time comparison studies for blade wax pattern production using rapid technologies (MJM technology and silicone
rubber molding) and conventional wax injection molding via machined aluminum tool were conducted and the res ults
tabulated in Tables (2). Comparing the time required to produce a wax pattern via
MJM technology and silicone rubber molding to employing aluminum mold in the conventional inves tment casting
process, significant time saving can be realized using rapid technologies.
In overall, s ilicone rubber molding technique can be use to build a few numbers of investment casting patterns of
blades without needing to complicated wax CNC machining operations and tooling but due to allowable dimensional
deviation of ±0.2mm for investment casting wax pattern of gas turbine blades , in terms of part accuracy, it isn’t successful
approach and significant improvements are still required to rectify the amounts of dimensional deviation encountered by the
patterns. It should also be noted that the silicone rubber molding is suitable for only small series production. It has the
advantages of much shorter lead times and lower production costs as compared to conventional tooling but considering it is
an indirect method (multi-step process), so compare with conventional machined aluminum tools it needs more
workmanships and human labor. However, for mass production, the conventional approach us ing tool steel for mold
fabrication is still the preferred choice mainly because of its strength and durability.
Table 2: Lead time comparison for investment casting pattern fabrication via different methods
MJM technology Silicone rubber molding Conventional tooling

Blade digitization+ surface modeling 4 days 4 days 4 days

Pattern design 1 day 1 day 1 day
Mold manufacturing Not required 24 h 3 week
Fabrication of 1×wax pattern 15 h 1h 1h

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5. Conclusion:
In this study there were used two different rapid technologies, namely, MJM and silicone rubber molding to make
investment casting pattern of Ruston TA 1750 gas turbine blade. This experimental study of two rapid technologies
indicated that they have opened up new cost-effective solutions for small-batch production of expendable pattern of gas
turbine blade. It observed that the MJM technology and silicone rubber molding can reduce both the cost and lead time
required for blade production. Dimensional inspection of built patterns by two mentioned methods indicated that MJM
technology had higher dimensional accuracy comparing with silicone rubber molding. Maximum deviation of built pattern
by ThermoJet system was -0.111mm.While maximum deviation of silicone rubber molding pattern was +0.298mm. Hence,
MJM technology has more ability to make patterns of parts with freeform surfaces such as gas turbine blades. Both
techniques are usable to manufacture expendable pattern of blade but silicone rubber molding is not proper method from
dimensional accuracy view of point.
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