Optimization of Geometric Parameters for Turbine Blades Based on Inverse Adjustments

2011 ◽  
Vol 341-342 ◽  
pp. 89-93
Author(s):  
Yang Liu Dou ◽  
Kun Bu ◽  
Yi Wei Dong ◽  
Yang Qing Dou
Keyword(s):  
Turbine Blade ◽  
Turbine Blades ◽  
Casting Process ◽  
Optimization Method ◽  
Geometric Parameters ◽  
Wax Pattern ◽  
Die Profile ◽  
Cavity Design ◽  
Profile Optimization ◽  
Deformation Compensation

In order to conform to the dimensional tolerances of wax pattern die-profile for turbine blade in investment casting process, an optimization method of geometric parameter for turbine blades based on inverse adjustment was proposed. The geometric parameters for optimizing were extracted, and the bending and torsional deformation can be compensation. Therefore the nonlinear deformation compensation during solidification and cooling procedure can be efficiently realized. This method finally exhibits its advantage over the traditional linear scaling method. It set the theoretical foundation on optimization method of die-cavity for turbine blade. The die-profile optimization system which was developed in this paper proves better effect for the die-cavity design.

The “Lost Wax” Process of Precision Casting

1950 ◽  
Vol 162 (1) ◽  
pp. 66-74 ◽  
Author(s):  
J. S. Turnbull
Keyword(s):  
Gas Turbine ◽  
Turbine Blades ◽  
Casting Process ◽  
Alternative Methods ◽  
Casting Technique ◽  
Gas Turbine Blades ◽  
Precision Casting ◽  
Good Surface ◽  
Wax Pattern ◽  
Good Surface Finish

The paper describes a casting process which differs from standard foundry practice in that it uses a wax pattern in a high refractory one-piece mould to produce metal castings with a good surface finish to an accuracy of ±0·002 inch. The process involves making a master pattern in either hard wood or metal, relating it to a soft metal die by precision casting technique, and then the production of wax patterns from the die on an injection machine. Finally, the wax patterns are invested in refractory moulds, the wax is melted out, the mould baked, and the metal component is cast. The “lost wax” process is advantageous in cases where ( a) the metal is unmachinable, or ( b) where the component is of an unmachinable shape, or ( c) where production by other methods takes too long. One of the most common applications is in the manufacture of gas-turbine blades. The tool costs are relatively low compared to the costs involved in alternative methods of manufacture, the die cost being a function of the number of castings required. The production of cheap castings is necessarily dependent on the scrap percentage being kept to a minimum; at present the scrap from the manufacture of gas-turbine blades is less than 30 per cent, and the author surmises that it would not be unreasonable to expect it to be less than 10 per cent in two years' time.

Aerodynamic Design and Modal Analysis on Wind Turbine Blade Based on CAD/CAE

2014 ◽  
Vol 952 ◽  
pp. 181-185
Author(s):  
Qian Qian Zhou ◽  
He Sun ◽  
Chun Bao Liu ◽  
Yang Wang ◽  
Xiao Guang Liu
Keyword(s):  
Wind Turbine ◽  
Modal Analysis ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Excitation Frequency ◽  
Optimization Method ◽  
Wind Turbine Blade ◽  
Wind Turbine Blades ◽  
Gradient Distribution ◽  
Design And Optimization

Wind turbine blade is an important component to capture wind energy and converse energy. Basing on Wilson optimization method and engineering pratice, 2MW wind turbine blade’s aerodynamic profile is designed. Meanwhile, in order to avoid the resonance damage, top 10 rank modal frequencies and displacement gradient distribution contours are obtained through modal analysis. The results show that blade’s natural frequency does not coincide with the external excitation frequency, which avoids the resonance damage. Blade’s major vibration forms are waving and shimmy, requiring the ability of excellent resisting torsion. Therefore, the design should enhance bending stiffness of the blade. This paper provides an effective method for large wind turbine blades’ design and optimization.

Aero Engine Test Experience With CMSX-4® Alloy Single-Crystal Turbine Blades

1996 ◽  
Vol 118 (2) ◽  
pp. 380-388 ◽  
Author(s):  
K. P. L. Fullagar ◽  
R. W. Broomfield ◽  
M. Hulands ◽  
K. Harris ◽  
G. L. Erickson ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Single Crystal ◽  
Turbine Blade ◽  
Hot Corrosion ◽  
Turbine Blades ◽  
Casting Process ◽  
Creep Rupture ◽  
Coating Performance ◽  
Turbine Engine ◽  
Mechanical Fatigue

A team approach involving a turbine engine company (Rolls-Royce), its single-crystal casting facilities, and a superalloy developer and ingot manufacturer (Cannon-Muskegon), utilizing the concepts of simultaneous engineering, has been used to develop CMSX-4 alloy successfully for turbine blade applications. CMSX-4 alloy is a second-generation nickel-base single-crystal superalloy containing 3 percent (wt) rhenium (Re) and 70 percent volume fraction of the coherent γ′ precipitate strengthening phase. Its finely balanced composition offers an attractive range of properties for turbine airfoil applications. In particular the alloy’s combination of high strength in relation to creep-rupture, mechanical and thermal fatigue, good phase stability following extensive high temperature, stressed exposure and oxidation, hot corrosion and coating performance, are attractive for turbine engine applications where engine performance and turbine airfoil durability are of prime importance. The paper details the single-crystal casting process and heat treatment manufacturing development for turbine blades in CMSX-4 alloy. Competitive single-crystal casting yields are being achieved in production and extensive vacuum heat treatment experience confirms CMSX-4 alloy to have a practical production solution heat treat/homogenization “window.” The creep-rupture data-base on CMSX-4 alloy now includes 325 data points from 17 heats including 3630 kg (8000 lb) production size heats. An appreciable portion of this data was machined-from-blade (MFB) properties, which indicate turbine blade component capabilities based on single-crystal casting process, component configuration, and heat treatment. The use of hot isostatic pressing (HIP) has been shown to eliminate single-crystal casting micropores, which along with the essential absence of γ/γ′ eutectic phase, carbides, stable oxide, nitride and sulfide inclusions, results in remarkably high mechanical fatigue properties, with smooth and particularly notched specimens. The Re addition has been shown not only to benefit creep and mechanical fatigue strength (with and without HIP), but also bare oxidation, hot corrosion (sulfidation), and coating performance. The high level of balanced properties determined by extensive laboratory evaluation has been confirmed during engine testing of the Rolls-Royce Pegasus turbofan.

Distributed Multidisciplinary Optimization of a Turbine Blade Regarding Performance, Reliability and Castability

2016 ◽  
Author(s):  
Clemens Buske ◽  
Alexander Krumme ◽  
Thomas Schmidt ◽  
Christian Dresbach ◽  
Sascha Zur ◽  
...  
Keyword(s):  
Turbine Blade ◽  
Design Process ◽  
High Performance ◽  
Structural Reliability ◽  
Casting Process ◽  
Optimization Method ◽  
Multidisciplinary Optimization ◽  
Aerodynamic Optimization ◽  
Process Simulations ◽  
Geometrical Constraints

Modern aero-engine blades are optimized for high performance and long service life, but manufacturing requirements are not considered adequately during the design process. Thus, time-consuming, iterative re-designs become necessary until a producible component evolves. The multidisciplinary design optimization method presented in this paper addresses not only the aerodynamic efficiency and structural reliability of a new turbine blade, but also ensures the castability of the design and thereby accelerates the entire design process and reduces the time-to-production. Because real casting process simulations are very time-intensive, they were substituted by checks of experimentally and numerically validated geometrical constraints. Different engineering tools were assembled in a joint process chain using an integration framework, which manages and distributes the calculations and hence the workload in a shared network. Based on a preliminary design of a new turbine section, the selected initial low pressure turbine blade was neither castable nor reliable. The multidisciplinary optimization achieved a blade design that satisfies the requirements for a successful casting process, has a low failure probability and, although not as high as from a pure aerodynamic optimization, exhibits an efficiency improvement.

Research on the Manufacturing of Steam Turbine Blade by Using Investment Casting Technology

2013 ◽  
Vol 789 ◽  
pp. 330-340 ◽  
Author(s):  
Hafid
Keyword(s):  
Steam Turbine ◽  
Turbine Blade ◽  
Investment Casting ◽  
Turbine Blades ◽  
Injection Pressure ◽  
Casting Process ◽  
Machining Process ◽  
Shape Accuracy ◽  
Casting Technology ◽  
Steam Turbine Blade

This paper presents the results of research on the manufacturing of steam turbine blade by using investment casting technology. Metal forming technology with precision casting process or investment casting is the right technology for the manufacture of turbine blades, because it can produce casting products that has advantages in size and shape accuracy, surface finish and the ability to produce thin casting, which the usually foundry can not be done. The purpose of this research is to produce a good quality of the casting products as an effort to reduce import dependency of steam turbine blade and to be the alternative way of making steam turbine blades in Indonesia, in addition to the machining process. Based on the experimentation trial implemented on casting products of stainless steel 304, the result indicates that the injection temperature for the wax NF-411 and optimal nozzle in hydraulic injection machine are 64°C and 30°C, injection pressure 1.75 MPa and injection time 9 seconds. The best casting induction furnace achieved at temperature 1,620°C as for to the number of ceramic mould coat which is good to be obtained at 7 layers. The testing results show that: (1) the chemical composition is appropriate with standard, (2) the hardness is 160 HB, (3) the shrinkage is 2.83%.

The Influence of Crystal Orientation on the Elastic Stresses of a Single Crystal Nickel-Based Turbine Blade

2011 ◽  
Vol 134 (1) ◽  
Author(s):  
Michael W. R. Savage
Keyword(s):  
Single Crystal ◽  
Turbine Blade ◽  
Fatigue Resistance ◽  
Crystal Orientation ◽  
Turbine Blades ◽  
Casting Process ◽  
Directionally Solidified ◽  
Element Analysis ◽  
Angle Variation ◽  
Elastic Stresses

Single crystal nickel-based turbine blades are directionally solidified during the casting process with the crystallographic direction [001] aligned with the blade stacking axis. This alignment is usually controlled within 10 deg, known as the Primary angle. The rotation of the single crystal about the [001] axis is generally not controlled and this is known as the Secondary angle. The variation in Primary and Secondary angles relative to the blade geometry means that the stress response from blade to blade will be different, even for the same loading conditions. This paper investigates the influence of single crystal orientation on the elastic stresses of a CMSX-4 turbine blade root attachment using finite element analysis. The results demonstrate an appreciable variation in elastic stress when analyzed over the controlled Primary angle, and are further compounded by the uncontrolled Secondary angle. The maximum stress range will have a direct impact on the fatigue resistance of the turbine blade. By optimizing the Secondary angle variation the elastic stresses can be reduced, giving the potential to enhance the fatigue resistance of the turbine blade.

Investigation on Material’s Creep Strength Variation Among Different Locations of Directional Solidified Turbine Blades

2014 ◽  
Author(s):  
Kai Zhang ◽  
Xiaojun Yan
Keyword(s):  
Turbine Blade ◽  
Creep Strength ◽  
Rupture Life ◽  
Turbine Blades ◽  
Casting Process ◽  
Body Part ◽  
The Body ◽  
Creep Tests ◽  
Strength Variation ◽  
Aero Engines

In order to obtain higher creep strength, the Directional Solidification (DS) Nickel-based turbine blades have been widely used in aero engines, because this advanced casting technology can improve the blade’s creep performance along the principal stress direction by forming columnar grains parallel to this direction. However, the grain structures at different regions of turbine blade are likely to be different, because the temperature field during casting process is affected by the different abrupt geometrical changes. Therefore, a variation in the creep performances at these regions is caused. To study the variation in creep strength among different regions of a DS turbine blade, this work designed and manufactured three types of DS specimens which have the geometry features of the platform, the shroud and the body part of DS turbine blade. Creep tests on these specimens were conducted under a stress level of 608MPa and temperature of 850 °C. The creep rupture life of platform-like and shroud-like specimens are about 93% and 73% of that of the body-like specimen respectively, which support that there exists a certain variation of creep strength among different regions in a DS turbine blade. It is suggested that the material’s creep strength variation among different locations of DS turbine blades should be considered in future turbine blade life design and prediction.

Determination of wax pattern die profile for investment casting of turbine blades

2011 ◽  
Vol 21 (2) ◽  
pp. 378-387 ◽  
Author(s):  
Yi-wei DONG ◽  
Kun BU ◽  
Yang-qing DOU ◽  
Ding-hua ZHANG
Keyword(s):  
Investment Casting ◽  
Turbine Blades ◽  
Wax Pattern ◽  
Die Profile

scholarly journals Aero Engine Test Experience With CMSX-4® Alloy Single Crystal Turbine Blades

1994 ◽  
Author(s):  
Keith P. L. Fullagar ◽  
Robert W. Broomfield ◽  
Mark Hulands ◽  
Ken Harris ◽  
Gary L. Erickson ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Single Crystal ◽  
Turbine Blade ◽  
Hot Corrosion ◽  
Turbine Blades ◽  
Casting Process ◽  
Creep Rupture ◽  
Coating Performance ◽  
Turbine Engine ◽  
Mechanical Fatigue

A team approach involving a turbine engine company [Rolls-Royce], its single crystal casting facilities and a superalloy developer and ingot manufacturer [Cannon-Muskegon], utilizing the concepts of simultaneous engineering, has been used to successfully develop CMSX-4 alloy for turbine blade applications. CMSX-4 alloy is a second generation nickel-base single crystal superalloy containing 3% (wt) rhenium (Re) and 70% volume fraction of the coherent γ′ precipitate strengthening phase. Its finely balanced composition offers an attractive range of properties for turbine airfoil applications. In particular the alloy’s combination of high strength in relation to creep-rupture, mechanical and thermal fatigue, good phase stability following extensive high temperature, stressed exposure and oxidation, hot corrosion and coating performance, are attractive for turbine engine applications where engine performance and turbine airfoil durability are of prime importance. The paper details the single crystal casting process and heat treatment manufacturing development for turbine blades in CMSX-4 alloy. Competitive single crystal casting yields are being achieved in production and extensive vacuum heat treatment experience confirms CMSX-4 alloy to have a practical production solution heat treat / homogenization “window”. The creep-rupture data-base on CMSX-4 alloy now includes 325 data points from seventeen heats including fourteen 3630 kg (8000 lb) production size heats. An appreciable portion of this data was machined-from-blade (MFB) properties which indicate turbine blade component capabilities based on single crystal casting process, component configuration and heat treatment. The use of hot-isostatic-pressing (HIP) has been shown to eliminate single crystal casting micropores which along with the essential absence of γ/γ′ eutectic phase, carbides, stable oxide, nitride and sulphide inclusions results in remarkably high mechanical fatigue properties, with smooth and particularly notched specimens. The Re addition has been shown to not only benefit creep and mechanical fatigue strength (with and without HIP), but also bare oxidation, hot corrosion (sulphidation) and coating performance. The high level of balanced properties determined by extensive laboratory evaluation has been confirmed during engine testing the Rolls-Royce Pegasus turbofan.

The Influence of Crystal Orientation on the Elastic Stresses of a Single Crystal Nickel-Based Turbine Blade

2011 ◽  
Author(s):  
Michael W. R. Savage
Keyword(s):  
Single Crystal ◽  
Turbine Blade ◽  
Fatigue Resistance ◽  
Crystal Orientation ◽  
Turbine Blades ◽  
Casting Process ◽  
Directionally Solidified ◽  
Element Analysis ◽  
Angle Variation ◽  
Elastic Stresses

Single crystal nickel-based turbine blades are directionally solidified during the casting process with the crystallographic direction [001] aligned with the blade stacking axis. This alignment is usually controlled within 10°, known as the Primary angle. The rotation of the single crystal about the [001] axis is generally not controlled and this is known as the Secondary angle. The variation in Primary and Secondary angles relative to the blade geometry means that the stress response from blade to blade will be different, even for the same loading conditions. This paper investigates the influence of single crystal orientation on the elastic stresses of a CMSX-4 turbine blade root attachment using finite element analysis. The results demonstrate an appreciable variation in elastic stress when analysed over the controlled Primary angle, and are further compounded by the uncontrolled Secondary angle. The maximum stress range will have a direct impact on the fatigue resistance of the turbine blade. By optimizing the Secondary angle variation the elastic stresses can be reduced, giving the potential to enhance the fatigue resistance of the turbine blade.

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