Purpose -The purpose of this paper is to present the advantages of computer-aided design/rapid prototyping (CAD/RP) usage in designing and manufacturing of the core models used for precise casting with direct and single solidification of aircraft engine turbine blade cores. Design/methodology/approach -The process of modelling three-dimensional CAD geometry of research blade in relation to the model of the core was presented with different wax types used in the RP technique. Findings -The geometry of the blade model has been designed in a way which allows making a silicon mould on the basis of a base prototype in the process of rapid tooling (RP/RT). Filing by different wax types was investigated in mean of the impact on filling accuracy of the mould cavity. Originality/value -The resulting models were used to make ceramic moulds and carry further work on the development of casting technology in the process of directional solidification and single crystal solidification of core blades of aircraft engines.

In this article the research related to the scope increase of incremental technology in machine industry is presented. Those technologies were used for the manufacture of components from polymeric materials with torque loaded such as: shafts, clutches of gear hubs and other elements of the propulsion system in which torque is transferred. To analyze the properties of the manufactured elements the original testing stand was designed and a series of preliminary torsional strength tests of the gear shaft fittings obtained using additive techniques have been carried out. On the basis of the obtained results it was stated that there is a clear influence of the printing plane in the applied incremental technologies [SLS (selective laser sintering) and FFF (fused filament fabrication)] on the torsion resistance of the obtained elements. The properties of the shafts also depend on the type of polymeric materials which they were made of.

Purpose The purpose of this paper is to present the methodology for manufacturing of aircraft transmission gears using incremental method of rapid prototyping (RP) – direct metal laser sintering (DMLS). The production of prototypes from metallic powders using described system allows the execution of final elements of complex structures with additional economic impacts. Design/methodology/approach The paper describes the use of selective laser sintering method (DMLS) by EOS Company. Whole chain of production of prototype is presented with the addition of geometric accuracy measurements by blue light laser device. Findings Presented in the research analysis of SLS/SLM technologies as rapid manufacturing systems shows that they can be applied in the production of prototypes used in the manufacturing process of gears for propulsion systems in aviation industry. Also, very important is the geometrical accuracy of gear prototypes produced by incremental methods. It determines subsequent treatment steps for aircraft propulsion system gears. Practical Implications The use of RP techniques as an alternative for conventionally used manufacturing method has mainly an economic impact related to the cost of time-consuming process and amount of defected elements appearing in serial production. Originality/value This paper presents possibility to use RP – DMLS system – for propulsion elements of aircraft structure. This research is original because of the complex description of the whole chain of manufacturing process. Additionally, geometrical accuracy measurement methodology by blue light presented with the RP method of manufacturing gives the research a unique characteristic.

Purpose The purpose of this paper is to present coordinate measuring system possibilities in the meaning of the geometric accuracy assessment of hot zone elements in aircraft engines. The aim of the paper is to prove that this method, which uses blue light and is most sufficient and cost-saving method, can to be used in the production line for serial manufacturing of elements, for which a high level of accuracy is required. Design/methodology/approach The analysis of the geometric accuracy of the blades was performed using non-contact optical coordinate scanner ATOS Triple Scan II Blue Light, manufactured by GOM Company, at the Department of Mechanical Engineering, Rzeszów University of Technology. Geometric analysis was conducted for blades manufactured from different waxes (A7Fr/60 and RealWax VisiJet CPX200), thus comparing injection technique and rapid prototyping (RP) method, and for casting made of Inconel 713C nickel-based superalloy. Findings The analysis of the criteria for the method of blades’ measuring selection showed that the chosen system successfully met all criteria for the verification of blades’ geometry at the selected stages of the process. ATOS II optical scanner with blue light technology allows measurement almost regardless of daylight or artificial (white) light. This allows the application of the measurement system in the production cycle, thus eliminating the need to create special conditions for measurements. Practical implications Requirements related to the accuracy of measured values, diversity and allowable measurement time are linked with the methods of production. Modern manufacturing methods based on computer-aided design systems/manufacturing/engineering systems require a non-contact optical measurement method based on the computer-aided-based coordinate measuring technique. In case of the non-contact optical scanning method based on the ATOS GOM measuring system, time and measurement costs depend on the methodology of measurement and the possibility of its automation. This is why the presented paper has a practical impact on possibilities for the automation of geometric accuracy measurements of obtained elements in the series production line. Social implications The use of ATOS Triple Scan II Blue Light by GOM Company allows the reduction of cost and time of production because of the possibility of the introduction of this system in an automated production line. Additionally, the measurement of hot section blades of aircraft engines by using the blue light method is much more accurate and has implication as it impacts safety of further used manufactured elements. Originality/value This paper presents the possibility of using the ATOS Triple Scan II Blue Light measuring system for geometric accuracy measurements in case of hot section blades of aircraft engines. This research is original because it describes three model geometric accuracy measurements, wax model obtained using the injection technique, wax model obtained using the I RP process and casting made of Inco...

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This study presents detailed characteristics of the DMLS method as used for titanium alloy powder with reference to a possible intended use in aeronautics applications.In the present study test models were made, designed for trials in which the model material properties are to be determined and which specify the basic features of the RP/DMLS technique. In order to evaluate the ultimate use of the DMLS technique in fabricating titanium alloy parts, the following procedures were conducted: tensile and upsetting tests for Ti6Al4V alloy samples (a comparative analysis for DMLS models and models fabricated, respectively, from titanium sheet and bar was carried out), an SEM analysis of the microstructure of the fragments of the surface of polished and etched samples, a Vickers hardness test and an analysis of the accuracy of the reproduction of the shape and roughness of the model fabricated in the DMLS procedure. A detailed analysis of the DMLS method significantly supplements the existing body of knowledge on innovative rapid prototyping techniques [1–4], and the results allow us to specify a group of aircraft structure components which may be fabricated using this method. Excellent strength properties of DMLS models and the possibility of improving surface quality by mechanical working enable the fabrication of advanced aircraft structure components operated in target conditions (under load).

In this work, on the example of a spline connection, the effect of 3D printing on the structure of machine elements made of polymeric materials after a torsion test was investigated. A clear influence of the type of polymer and the printing direction in the applied incremental technology [FFF (Fused Filament Fabrication) also known as FDM (Fused Deposition Modeling)] on the structure of the obtained elements was observed.

The above paper presents the example of sub-frame connections with the hull in a small training aircraft and the results of the analysis of a selected connection using the method of reflected light. The connection model was subjected to the loads similar to those existing in a structure using various materials of the connection. Thus, photoelastic deformation image, showing the load applied on the joint was obtained. Then, for the materials used in the model, photoelastic constants were determined, which were used to estimate the stress values in the model. The analysis allowed us to determine the effect of kind and features ( mainly hardness) of the used material pads, on mechanical behavior of the elements of joint.Keywords: photoelastic, reflected light, photoelastic constant, connections, stress W artykule przedstawiono wyniki analizy wybranego połączenia z wykorzystaniem metody światła odbitego na przykła-dzie połączenia ramy silnika z kadłubem w małym samolocie szkolno-treningowym, Model połączenia poddano obciążeniom zbliżonym do rzeczywistych występujących w konstrukcji przy zastosowaniu różnych materiałów konstrukcyjnych elementów składowych połączenia. Otrzymano obraz pól odkształceń będący odpowiedzią węzła na zadane obciążenie. Następnie dla materiałów zastosowanych w modelu wyznaczono stałe elastooptyczne, które posłużyły do oszacowania wielkości naprężeń występujących w modelu. Przeprowadzona analiza pozwoliła na określenie wpływu rodzaju i właściwości (głównie twardości ) materiału zastosowanej podkładki na zachowanie się pozostałych elementów węzła.