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10007877
Application of Powder Metallurgy Technologies for Gas Turbine Engine Wheel Production
Abstract:
A detailed analysis has been performed for several schemes of Gas Turbine Wheels production based on additive and powder technologies including metal, ceramic, and stereolithography 3-D printing. During the process of development and debugging of gas turbine engine components, different versions of these components must be manufactured and tested. Cooled blades of the turbine are among of these components. They are usually produced by traditional casting methods. This method requires long and costly design and manufacture of casting molds. Moreover, traditional manufacturing methods limit the design possibilities of complex critical parts of engine, so capabilities of Powder Metallurgy Techniques (PMT) were analyzed to manufacture the turbine wheel with air-cooled blades. PMT dramatically reduce time needed for such production and allow creating new complex design solutions aimed at improving the technical characteristics of the engine: improving fuel efficiency and environmental performance, increasing reliability, and reducing weight. To accelerate and simplify the blades manufacturing process, several options based on additive technologies were used. The options were implemented in the form of various casting equipment for the manufacturing of blades. Methods of powder metallurgy were applied for connecting the blades with the disc. The optimal production scheme and a set of technologies for the manufacturing of blades and turbine wheel and other parts of the engine can be selected on the basis of the options considered.

References:

[1] L.A. Magerramova, B.E. Vasilyev, V.S. Kinzburski, “Novel designs of turbine blades for additive manufacturing,” in Proc. TurboExpo2016 Conf., Seoul, 2016, GT2016-56084.
[2] L.A. Magerramova, B.E. Vasilyev, “Advanced gas turbine engines blades: biologically-based design and additive technology implementation,” Paper presented at 8th Int. Conf. Beam technologies and laser application, St. Petersburg, 2015, unpublished.
[3] L.А. Magerramova, Е.P. Kratt, Т.P. Zakharova, V.V. Yacinsky, “Тhe structural and technological design feature of bimetallic blisks for high temperature gas turbine aviation engines,” in Proc. 2nd European EUCASS Conf., Brussels, 2007 CD.
[4] L. A. Magerramova, “The project development of HIPed Bimetallic Blisk with Uncooled and Cooled Blades for Engine Gas Turbine of Difference Using,” in Proc. HIP’14 Int. Conf., Stockholm, 2014, id: 140605-1035.
[5] L.A. Magerramova, “Achievement of bimetallic blisks integrate dissimilar alloys for promising high temperature aviation gas turbine engines,” in Proc. 28th Congress of the International Council ICAS 2012. Brisbane, 2012, ID No: 224. CD.
[6] L.A. Magerramova, Е.P. Kratt “A method of manufacturing an integrated turbine blisks of various metal alloys for gas turbine engine,” Ru patent #2579558, Published on 08.02.2016.
[7] L.А. Magerramova, Е.P. Krat., V.V. Yacinsky, “A method of manufacturing integral blisks with cooled blades, integrated blisk and cooled blade for gas turbine engine,” Ru patent #2478796, Published on 10.04.2013.
[8] Jason C. Fox, Shawn P. Moylan, Brandon M. Lane, “Effect of Process Parameters on the Surface Roughness of Overhanging Structures in Laser Powder Bed Fusion Additive Manufacturing” Procedia CIRP, Volume 45, 2016, Pages 131-134.
[9] S.O. Onuh, K.K.B. Hon, “Optimising build parameters for improved surface finish in stereolithography”, International Journal of Machine Tools and Manufacture, Volume 38, Issue 4, March 1998, Pages 329-342
[10] L.A. Magerramova, S.S. Baculin, “The method of positioning the blades in the manufacture of integral blisks turbine of a gas turbine engine,” Ru patent #2595331, Published on 03.08.2016
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