Design, Prototyping and Preliminary Testing of a Ti-Al Gas Turbine Blade

2015 ◽  
Author(s):  
Roberto Capata ◽  
Enrico Sciubba ◽  
Luigi Menna ◽  
Andrea Brotzu ◽  
Ferdinando Felli ◽  
...  
Keyword(s):  
Turbine Blade ◽  
Molten Metal ◽  
Investment Casting ◽  
Gas Turbines ◽  
Fused Deposition Modeling ◽  
Fluid Dynamic ◽  
Mechanical Tests ◽  
Temperature Fields ◽  
Mold Material ◽  
Fused Deposition

This work investigates the feasibility of manufacturing a turbine blade made of a Ti-Al intermetallic alloy by means of investment casting. The work is based on a multidisciplinary approach that combines a conventional CFD analysis of the flow field around the statoric and rotoric blades with the results of several metallurgical studies aimed at the optimization of the alloy composition by finding the best compromise among fracture toughness, oxidation resistance at high temperatures and mechanical properties. The combination of the two techniques lead to an iterative procedure (of which only the first two steps are reported in this paper): a conventional blade is first modeled and the corresponding investment cast is produced via a 3D printing technique; a first version of the blade is built; a modified blade shape is then obtained by a refined CFD study; as a last step the final version of the blade is cast. On the basis of standard operational specifications representative of modern gas turbines, a turbine blade was therefore designed, tested by CFD (ANSYS-FLUENT) to ensure proper fluid dynamic performance, and its levels of thermo-mechanical stress under working conditions were calculated via a commercial CAD software (ANSYS). The fully 3D version of the component was subsequently prototyped by means of fused deposition modeling. A full-scale set of blades (blade height approximately 7 cm, blade chord approximately 5 cm) was produced by means of investment casting in an induction furnace. The produced items showed acceptable characteristics in terms of shape and soundness. The blade alloy was analyzed by performing metallographic investigations and some preliminary mechanical tests. At the same time, the geometry was refined by a complete and more complex CFD study, and a slightly modified shape was obtained. Its final testing under operative conditions is left for a later study. The paper describes the spec-to-final product procedure and discusses some critical aspects of this manufacturing process such as the considerable reactivity between the molten metal and the mold material, the resistance of the ceramic shell to the molten metal impact at temperatures as high as 2073 K and the limit mold porosity that may compromise the component surface finish. Furthermore, a detailed account is provided for the CFD results that led to the modification of the original commercial shape: pressure, velocity and temperature fields in the statoric and rotoric channels are described in some detail, and a preliminary performance assessment of the turbine stage is presented and discussed.

Preliminary Design, Modeling, Production, and First Evaluation Tests of a Ti–Al Gas Turbine Blade

2017 ◽  
Vol 139 (3) ◽  
Author(s):  
Andrea Brotzu ◽  
Roberto Capata ◽  
Ferdinando Felli ◽  
Daniela Pilone ◽  
Enrico Sciubba
Keyword(s):  
Gas Turbine ◽  
Molten Metal ◽  
Manufacturing Process ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Mechanical Tests ◽  
Mold Material ◽  
Micro Gas Turbine ◽  
Fused Deposition ◽  
Project Phases

The aim of this work is to design a lightweight, creep-resistant blade for an axial single-stage micro-gas turbine. The selected process was casting of an intermetallic titanium/aluminum alloy. All the project phases are described, from the preliminary thermodynamic and geometric stage design, to its three-dimensional (3D) modeling and the subsequent finite element method–computational fluid dynamics (FEM-CFD) analysis, to the manufacturing process of the single rotor blade. The blade making (height 7 cm and chord 5 cm, approximately) consisted in a prototyping phase in which a fully 3D version was realized by means of fused deposition modeling and then in the actual production of a full-scale set of blades by investment casting in an induction furnace. The produced items showed acceptable characteristics in terms of shape and soundness. Metallographic investigations and preliminary mechanical tests were performed on the blade specimens. The geometry was then refined by a CFD study, and a slightly modified shape was obtained whose final testing under operative conditions is though left for a later study. This paper describes the spec-to-final product procedure and discusses some critical aspects of this manufacturing process, such as the considerable reactivity between the molten metal and the mold material, the resistance of the ceramic shell to the molten metal impact at high temperatures, and the maximal acceptable mold porosity for the specified surface finish. The CFD results that led to the modification of the original commercial shape are also discussed, and a preliminary performance assessment of the turbine stage is presented and discussed.

Investigations for Mechanical Properties of Hybrid Investment Casting: A Case Study

2014 ◽  
Vol 808 ◽  
pp. 89-95 ◽  
Author(s):  
Parlad Kumar ◽  
Rupinder Singh ◽  
I.P.S. Ahuja
Keyword(s):  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Manufacturing Processes ◽  
Biomedical Implant ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Investment Casting Process

Conventional investment casting is one of the old manufacturing processes. It involves expensive tooling for making sacrificial wax patterns to make ceramic moulds. However, with the emergence of rapid prototyping technologies, now it is possible to make and use plastic patterns instead of wax patterns along with some advantages. In this paper, plastic patterns have been prepared by using fused deposition modeling and used for investment casting process. A case study has been discussed to make a biomedical implant by the hybridization of fused deposition modeling with investment casting. Dimensional accuracy, surface finish and hardness of the casted biomedical implants have been tested and reported.

Evaluation of Direct Rapid Prototyping Pattern for Investment Casting

2012 ◽  
Vol 463-464 ◽  
pp. 226-233 ◽  
Author(s):  
M.F.M. Omar ◽  
S. Sharif ◽  
M. Ibrahim ◽  
H. Hehsan ◽  
M.N.M. Busari ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Ceramic Powder ◽  
Dimensional Accuracy ◽  
Fused Deposition ◽  
Rp Process ◽  
Burn Out ◽  
Quality Assessments

The ability of rapid prototyping (RP) technology to fabricate direct part of any complex shape as a sacrificial pattern in shorter lead time has benefited the foundry industries significantly. The quality of investment casting (IC) parts is directly related to the master pattern fabricated from RP process. The main objective of this study was to evaluate the quality characteristics of various RP patterns that were fabricated by various RP processes which include 3D Printer (3DP), Fused Deposition Modeling (FDM) and Multijet Modeling (MJM). Evaluation of the RP patterns was carried out on dimensional accuracy, surface roughness and pattern shrinkage. Different internal pattern designs for the RP parts were developed using Insight software for FDM process and Solidworks 2011 for other RP systems. In addition to the quality assessments, the effect of the internal pattern designs on the burn out behaviour of the RP patterns was also evaluated. Experimental results showed that FDM and MJM produced patterns with better accuracy, surface roughness and part shrinkage when compared to 3DP. It was evident that the internal pattern structure improved the accuracy of the patterns produced from all RP processes. Results showed that FDM and MJM processes were superior in terms of mold cleanliness when no residual ash was observed during the burn out stage. Significant oxidation of ceramic powder was observed on the molds of the 3DP patterns which need to be removed manually from the molds.

scholarly journals Mechanical, Thermal and Microstructural Characteristic of 3D Printed Polylactide Composites with Natural Fibers: Wood, Bamboo and Cork

2021 ◽  
Author(s):  
Karolina E. Mazur ◽  
Aleksandra Borucka ◽  
Paulina Kaczor ◽  
Szymon Gądek ◽  
Rafał Bogucki ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Elevated Temperatures ◽  
Fiber Type ◽  
Mechanical Tests ◽  
Degree Of Crystallinity ◽  
Scanning Calorimetry ◽  
Fused Deposition ◽  
The Impact ◽  
Different Levels ◽  
Natural Fillers

AbstractIn the study, polylactide-based (PLA) composites modified with natural particles (wood, bamboo, and cork) and with different levels of infilling (100%, 80%, and 60%) obtained by fused deposition modeling were tested. The effect of fiber type, infill level and crystallization rate on the mechanical properties were investigated by using tensile, flexural, and impact tests. The materials were subjected to mechanical tests carried out at 23 and 80 °C. Differential scanning calorimetry were employed to analyze crystallization behavior of composite. Furthermore, hydrothermal degradation was performed, and its effect on the properties was analyzed. The addition of natural fillers and different levels of infilling result in a similar level of reduction in the properties. However, the addition of natural fillers resulted in a slightly lower drop than the lowered infilling rate − 40% and 50% for tensile strength, respectively. Moreover, it was found that, composites made of PLA are more sensitive to high temperatures than to water. The decrease in Young's modulus of PLA at 80 °C was 90%, while after 28 days of hydrodegradation ~ 9%. The addition of fibers reduced this decrease at elevated temperatures. Importantly, in the case of a brittle material such as PLA, the impact strength has been improved by 50% for composites with cork particles and other lignocellulosic composites remained at the same level as for resin. Generally, the thermal treatment of composites increased the degree of crystallinity of the materials, as reflected in the higher results of mechanical tests.

Controlled Porosity Ceramics for Bone Graft Applications

2000 ◽  
Author(s):  
S. Bose ◽  
J. Darsell ◽  
R. Kintner ◽  
K. Feely ◽  
H. L. Hosick ◽  
...  
Keyword(s):  
Pore Size ◽  
Fused Deposition Modeling ◽  
Mechanical Tests ◽  
In Vitro Tests ◽  
Slice Thickness ◽  
Connective Tissues ◽  
Fused Deposition ◽  
Significant Research ◽  
Controlled Porosity

Abstract Significant research has already been done for the development of bioceramic materials with controlled microstructures using inert, bioactive and bioresorbable ceramics. Microporous implants with controlled pore size in the range of 100-600 μm have proven to be osteoconductive. A minimum pore size of 100 μm is necessary for tissue in-growth and to provide blood supply to the connective tissues to keep them viable and healthy. Bone in-growth takes place within the inter-connected pore channels near the surface and maintains its vascularity and long term viability, and the implant serves as a structural bridge or scaffold for bone formation. Controlled porosity ceramic scaffolds were fabricated using indirect fused deposition modeling (FDM), a commercially available rapid prototyping process, with alumina and tricalcium phosphate (TCP) ceramics. Pore size and pore volumes were varied by changing road width, road gap and slice thickness of the polymeric molds. Mechanical tests were conducted to understand the influence of porosity parameters on strength degradation. In vitro tests were carried out with human osteoblast (HOB) cells to understand the effects of porosity parameters on cell growth. The paper describes the effects of porosity on the biocompatibility and bio-mechanical properties of controlled porosity alumina and TCP scaffolds.

Requirements Selection for Rapid Prototyping: Polyphenylsulfone as a Mold Material for Spin Casting Polyurethane Resin

2009 ◽  
Author(s):  
Thomas Martens ◽  
Laine Mears ◽  
Mike Dotson ◽  
Monty Graham ◽  
Phillip Sanger
Keyword(s):  
Rapid Prototyping ◽  
Process Design ◽  
Fused Deposition Modeling ◽  
Scale Model ◽  
Mold Material ◽  
Spin Casting ◽  
Fused Deposition ◽  
Polyurethane Resin ◽  
Deposition Modeling ◽  
Selection For

For the development of a rotational symmetrical polyurethane part with a steel reinforcement, a requirement/constraint driven approach to process design has been taken. In this approach a scale model of the process was built using fused deposition modeling rapid prototyping technique, then used to validate design, material and process parameters. After selection and testing on the scaled prototype, results were used to define a full-sized spin casting mold built using Polyphenylsulfone.

Investigations for statistically controlled investment casting solution of FDM-based ABS replicas

2014 ◽  
Vol 20 (3) ◽  
pp. 215-220 ◽  
Author(s):  
Rupinder Singh ◽  
Gurwinder Singh
Keyword(s):  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Dimensional Accuracy ◽  
International Standard Organization ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Standard Organization ◽  
Measuring Machine

Purpose – The purpose of the present study is to investigate statistically controlled investment casting (IC) solution of fused deposition modeling (FDM)-based ABS replicas. Design/methodology/approach – The work started with the identification of the benchmark/component. Prototypes (to be used as pattern) were built on FDM with ABS plastic material, followed by IC. The measurements on final casting prepared were made on the co-ordinate measuring machine (CMM) from which international tolerance (IT) grades were calculated to establish the dimensional accuracy of the components. Findings – This study further highlighted the cast component properties (like hardness and surface finish) for suitability of this process. Final castings produced are acceptable as per international standard organization (ISO) standard UNI EN 20286-I (1995). Originality/value – This process ensures development of statistically controlled IC solution as technological prototypes and proof of concept at less production cost and time.

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