Application of Rapid Prototyping Technology in the Manufacturing of Turbine Blade With Small Diameter Holes

Abstract

The article presents the possibilities++ of using Rapid Prototyping (RP) technology in the manufacturing of turbine blades with small diameter holes. The object under investigation was gas turbine blade with small diameter cooling holes and holes for generating longitudinal vortices. A turbine blade model was produced by means of Direct Metal Laser Sintering (DMLS) technology and subsequently validated in terms of detection and accuracy of the obtained holes. The application of the computer tomography and digital radiography technique resulted in obtaining a series of cross-sections of the turbine blade model with a series of holes. Particular attention was pointed out at the investigation of the locations of micro-holes with a diameter of 0.3 mm. It turned out that it was impossible to make such small holes by the RP method. In the following part the results of the study on the possibilities of making the micro-holes using electrical discharge method have been presented. In addition, proposition of further works such as the development of the considerations and issues discussed in this article, has been offered.

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

“…Additive Manufacturing (AM), commonly referred to as incremental or 3D printing technology, refers to the layered construction of objects based on 3D computer models with complex inner [ 36 , 37 ] or outer [ 4 ] geometries. A 3D computer model is created in CAD software used for computer aided design (CAD) or obtained as a cloud of points by 3D scanning [ 38 ].…”

“…Currently, mainly AM powder methods with metals and their alloys are used to build fully functional and responsible mechanical parts. Elements of this type are used in the aerospace, offshore, and energy sectors [ 36 , 74 , 75 ] as well as in the automotive, electronics, medical [ 76 , 77 ] and tool industries [ 78 , 79 ], among others.…”

“…One of the essential structural elements of the presented blade, which needs to operate under high-temperature conditions, is the proper design of its inner features, ensuring cooling medium flow and effective separation of blade material from hot gases. The results presented in [ 36 ] indicated that the sintering process did not make it possible to make the holes of the diameter equal to 0.3 mm with the angular position. This revealed the limitations in application of selective laser melting technology with respect to making holes with a diameter smaller than 1 mm.…”

“… 3D printing process chain for the example of a turbine blade produced by means of DMLS technique with the use of EOS Maraging Steel MS1 in the form of powder; based on references [ 36 , 37 ]. …”

Application of Reverse Engineering Technology in Part Design for Shipbuilding Industry

“…The use of modern measurement techniques in combination with additive techniques makes it possible to produce a wide variety of parts needed, for instance, to repair damaged devices on ships or offshore steel structures [6,18], or in the automotive industry [15]. A structurally advanced group of products with complex geometry and higher-quality surface requirements are high-pressure stage blades in gas turbines used in ship propulsion systems or in Tesla turbines.…”