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Selection of Manufacturing Process for Aeroengine Gas Turbine Blades

Research · November 2015

DOI: 10.13140/RG.2.1.2600.9046

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Alok Singh Chauhan

Defence Research and Development Organisation
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 Manufacturing Process Selection for
Aerospace Gas turbine blades & vanes
 Vane / Blade Materials :
Temperature- Pressure

125 Evasion
Super Alloys like CM 247, Take -off
Air
RENE 80 100
work Bomb Combat
Climb Touch
and go
 Disc / Casing Materials : 75

Udimet 720, INCO 718, 50 Ferry

Powder metallurgy discs 25

 Coatings: Platinum 0

Aluminide Thermal Barrier Loading Spectrum Time - Minute ( Approximate)

Coatings
Cross Section of a Gas Turbine (P-T Distribution)

Complex environment & Loads

1. Centrifugal
2. Thermal
3. Steady
4. Vibration
5. Fatigue
External Shape
6. Fluctuating pressure fields
7. Creep
8. Mechanical stress -80%
Sections Showing Internal Cooling Channels UTS,
Produced by Ceramic Cores
Alok Singh Chauhan, MED IIT Bombay
Internal Core
 Manufacturing Process Selection

Process Requirements for the Gas turbine blades

Function: Gas Turbine Blade -Power Extraction
Constraints : Material: Ni Based Super Alloy
Shape: 3D hollow Technical constraints
Mass: 0.3-1.2 kg
Minimum section: 1.5 mm
Tolerance: < ± 0.1 mm Quality constraints
Surface roughness: < 2.0 μm
Batch size: 1000 Economic constraints

Objective: Minimize cost

Free variables: Choice of Manufacturing process

Alok Singh Chauhan, MED IIT Bombay

 Manufacturing Process Selection
Component Material Mass of Component

External Shape

Internal Core Alok Singh Chauhan, MED IIT Bombay

 Manufacturing Process Selection
Tolerance Minimum Section Thickness

External Shape

Internal Core Alok Singh Chauhan, MED IIT Bombay

 Manufacturing Process Selection
Roughness Economic Batch Size

External Shape

Internal Core Alok Singh Chauhan, MED IIT Bombay

 Manufacturing Process Selection

Shape of Component

External Shape
Internal Core Alok Singh Chauhan, MED IIT Bombay
 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: Creep feed grinding
• Bond Coat
Alok Singh Chauhan, MED IIT Bombay EDM / Laser drilling
• Thermal Barrier Coating
 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.

Alok Singh Chauhan, MED IIT Bombay

REFERENCES
1. Sarojrani Pattnaik, D. Benny Karunakar, P.K. Jha,; Developments in investment casting process—A review,
Journal of Materials Processing Technology 212 (2012) 2332– 2348.
2. 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. 73-80
3. 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 ) 1714 – 1722
4. 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 247-248
5. Vijayakumar M., “Process Technology for making Sintered Ceramic Cores”, Metals Materials and Processes, 2007,
Vol 19, No. 1-2, pp 77-92
6. The Jet Engine, The Technical Publication department,Rolls-Royce plc, 5th edition (1996), ISBN 0902121 235

Alok Singh Chauhan, MED IIT Bombay

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