Fabrication Of Turbine Blades Research Articles

Sacrificial ceramics powders mix for titanium alloys complex shapes production by hybridization of SPS and 3D printing

The production of complex shapes via Spark Plasma Sintering (SPS) is challenging due to intricate die configurations. The “DEFORMINT” approach combines 3D printing with SPS and sacrificial powder to fabricate fully dense shapes. Using the same powder for both the component and sacrificial part avoids distortions, but high costs of titanium alloys like Ti-6Al-4 V are limiting. This study tested a low-cost ceramic powder that mimics Ti-6Al-4 V's behavior, forming a pseudo-isostatic configuration above 1250 K. SPS experiments established a densification model and predicted distortions in a thick cone and a thin, complex turbine blade, showing good correlation with experimental results. The new sacrificial mix does not imply additional deformation and allows the fabrication of turbine blades. The only defect is a 600 μm skin effect at the contact interface.

Vibration Analysis using Finite Element Analysis (FEA): An Evaluation of Pico-Tubular Bulb Type Turbine Blades Fabricated in Composite Materials

Tubular turbines have been widely employed and evolved fast when its introduction in the 1930s due to their strong technical and economic qualities and application. Because its performance and structure differ from those of ordinary vertical shaft units, local and international academics worked extensively on research techniques and technological means using numerical simulation and model testing. The transmissions of a high quantity of power, which may cause unwanted vibrations that reduce efficiency, increase wear, and, in the worst-case scenario, cause serious damage. In this paper, the material propose in order to substantiate that the random excitations and excess vibration of the pico-turbine can be prevented is the use of CFRP (carbon fiber reinforced polymer) and PLA (polylactic acid). In this paper, ANSYS® Mechanical modal simulation is used to evaluate the structures’ robustness behavior of the composite materials that were used as the main material in the fabrication of turbine blades for bulb-type turbine application. The use CFD simulation in SOLIDWORKS® is needed to examine the pressure fluctuation caused by unsteady flow that can contribute in the unwanted pulsation and to conform the modal simulation results. To validate the results, pressure pulsation experimentation is conducted to evaluate the fluctuation of the pressure affecting the blades or in the rotating region and it is analyzed through frequency response domain. Hence, in this paper, it is proven that the vibration behavior of the material is acceptable since the resulting natural frequency provides resulting stress, strain, and deformation that is allowable and below its ultimate tensile strength.

Development of Composite Material for Wind Turbine Blades

Rapid increases in the prices of conventional turbine blade making materials as well as future sustainability issues is attracting research interest in the development of polymer composites for turbine blade applications. This study examines the suitability of using a novel bamboo fibre and recycled plastics composite developed for wind turbine blade application. Bamboo fibre was extracted from raw bamboo by chemical and mechanical processes. Recycled High Density Polyethylene (HDPE) was collected, cut into pieces, cleaned and combined with extracted bamboo fibre to form the composite. The percentage ratio of fibre content in the ten specimens ranged from 2.5% to 25%. A series of mechanical tests were conducted on the specimens, including tensile test, impact test, water absorption test and sun radiation test. Results established that as the percentage of bamboo fibre in the specimen increased, the tensile strength and impact energy also increased. Water absorption and sun radiation tests conducted on specimen X revealed no meaningful impact its mechanical properties. Hence, the most significant deduction from this study is that the specimen with 25% bamboo fibre and 75% HDPE matrix possesses the quality that qualifies it to be used as a material for wind turbine blade fabrication.

Novel approach to investment casting of heat-resistant steel turbine blades for aircraft engines

Defects that form during the investment casting of turbine blades for aircraft engines pose a serious hazard to flight safety and greatly increase the costs associated with manufacturing. In this study, we conducted numerical simulations based on a retained melt modulus model to analyze the flow of metals through molds in order to determine the probability of shrinkage defect (PSD) in heat-resistant steel (SCH12) turbine blades for aircraft engines. The results of preliminary simulations and experiments were used to guide the establishment of simulations based on four casting schemes. Our objective in this stage was to identify the casting scheme with the lowest PSD. We then implemented the best of the four schemes with the bottom of the casting system immersed in cold water. We also incorporated virtual thermo-dynamical sensors in the simulations to characterize the effects of water depth on the rate and direction of solidification in the mold cavity. We then applied the optimal investment casting conditions to the fabrication of turbine blades in an established foundry. X-ray analysis detected almost none of the detrimental defects commonly associated with this type of casting, thereby demonstrating the efficacy of the proposed scheme.

A Metallographic Review of 3D Printing/Additive Manufacturing of Metal and Alloy Products and Components

Applications and examples of light and electron micrographs illustrating microstructures, which describe metallurgical phenomena in 3D printing/additive manufacturing of metal and alloy products and components, are presented along with extensive process and processing parameter descriptions and review. Examples include microstructures that have defined turbine blade fabrication and optimization over the past half century, including contemporary electron beam melting fabrication of turbine blade alloys and other novel microstructures and architectures, which result from layer by layer, non-equilibrium melt solidification and epitaxial growth involving powder bed laser and electron beam fabrication. Phase transformations and second-phase formation by rapid cooling in metal and alloy components fabricated by laser and electron beam melting technologies are illustrated for a range of high-temperature materials. Using a range of examples, the advantages of fabricating complex (especially porous) biomedical and related commercial products are described. Prospects for future developments of direct 3D metal and alloy droplet printing, as a key component of the digital factory of the future, are described. This technology is compared with more conventional solidification and powder bed layer building thermo-kinetics, especially in the context of large structure and component fabrication.

Fabrication of nano-TiCp reinforced Inconel 625 composite coatings by partial dissolution of micro-TiCp through laser cladding energy input control

Nano-particulate reinforced metal matrix composites (nPRMMCs) exhibit excellent comprehensive properties unmatched by conventional micro-particulate reinforced metal matrix composites (μPRMMCs). However, current techniques for fabricating nPRMMCs usually use nano-powders as raw materials, which are not preferred due to their agglomeration trend and harmful size. In this paper, we developed a technique to fabricate nano-TiCp reinforced Inconel 625 composite coatings by laser cladding of an Inconel 625+5wt.% TiC powder mixture, particle size of the raw powders both in micrometer range. By controlling the specific energy input, the micro-TiCp partially dissolved into nanometer scale. The influence of specific energy input on particle size, morphology and the microstructure, phase constitution and mechanical properties of the composite coatings were investigated by scanning electron microscopy, X-ray diffraction, transmission electron microscopy and nano-indentation test. Nano-TiCp reinforced Inconel 625 composite coatings were achieved at the specific energy input of 25.3kJ/g. The hardness and modulus of the nPRMMCs are 3.36GPa and 190.91GPa, increased by 10.33% and 12.39% respectively compared to laser cladded Inconel 625 substrate. The nPRMMCs show potential in applications such as the fabrication of turbine blades and engine components with improved performance.

Multi-Agent Tool Management in the Manufacturing of Aircraft Engines

A Multi-Agent Tool Management System (MATMS) for automatic tool procurement in a supply network was developed and implemented. The MATMS realization involved the engineering design of an agent system that operates in the framework of a negotiation-based multiple-supplier network where an aircraft engine producer (buyer) requires from external tool manufacturers (sellers) the purchase of new cubic boron nitride (CBN) grinding wheels and the performance of dressing operations on worn-out CBN grinding wheels for turbine blade fabrication. The main purpose of the MATMS is the optimized tool management for nickel-based alloy turbine blade grinding while operating in a supply environment made uncertain by external tool manufacturers providing unreliable tool delivery time responses.

Wetting and interactions of Ni- and Co-based superalloys with different ceramic materials

In this work, a systematic study of the wetting behavior of two Ni-based and one Co-based superalloys, used, in particular, for the fabrication of turbine blades, is presented with reference to different ceramic substrates: sapphire, polycrystalline alumina, zirconia, and mullite. Wettability tests have been performed by means of the “sessile drop” method at 1500 °C; the characterization of the interfaces between the molten drop and the substrates has been performed by SEM/EDS analysis in order to check the final characteristics of the solidified interfaces. The results are discussed in terms of chemical interactions in relation to the processing parameters and as a function of the surface and interfacial, morphological and energetic properties of the systems.

Emergent synthesis in supply network tool management

This work fits into a wider research on supply chains concerned with the development and implementation of a Multi-Agent Tool Management System (MATMS) for automatic tool procurement in a supply network. The main purpose of the MATMS is the optimised management of CBN grinding wheels for nickel base alloy turbine blade fabrication while operating in a multiple-supplier network environment made uncertain by external tool manufacturers showing unreliable tool delivery time response. Emergent synthesis concepts for tool management are analysed and discussed, and the design and functioning of Flexible Tool Management Strategies (FTMS), founded on an emergent synthesis methodology based on neuro-fuzzy paradigms, is illustrated. The FTMS paradigms, integrated in the MATMS as domain specific problem solving functions of the agent responsible tool inventory sizing and control, are proposed as dependable and robust toll delivery time forecasting methods, founded on knowledge evolution, for the solution of this Class II synthesis problem. The evaluation and comparison of the FTMS performance is carried out with reference to real industrial cases of CBN grinding wheel tool management.

Grinding Wheel Management through Neuro-Fuzzy Forecasting of Dressing Cycle Time

A multiple supplier tool management system based on reliable tool delivery forecasting is developed for optimum tool inventory sizing. The system is built up on the basis of historical data on tool management comprising the series of tool shipment and delivery dates between one manufacturing company and several external tool manufacturers in a supply network. If historical data are highly variable due to the incidence of uncertain but not random factors, classical time series analysis cannot measure the Imprecision deriving from events that are neither stochastic nor casual. An alternative is given by the analysis through intelligent computing techniques capable to deal with deterministic events but also take into account unpredictable factors for better results in prediction and forecast. A neuro-fuzzy system is used in this paper to approach optimum tool inventory sizing of CBN grinding wheels for nickel base alloy turbine blade fabrication.

Hygrothermomechanical Evaluation of Transverse Filament Tape Epoxy/Polyester Fiberglass Composites

Transverse filament tape (TFT) fiberglass/epoxy and TFT polyester composites intended for low cost wind turbine blade fabrication have been subjected to static and cyclic load behavior tests whose results are presently evaluated on the basis of an integrated hygrothermomechanical response theory. Laminate testing employed simulated filament winding procedures. The results obtained show that the predicted hygrothermomechanical environmental effects on TFT composites are in good agreement with measured data for various properties, including fatigue at different R-ratio values.