Review of main manufacturing processes of complex hollow turbine blades

References

• Aguilar , J. , Schievenbusch , A. , and, Kaettlitz , O ., 2011 . Investment casting technology for production of TiAl low pressure turbine blades - Process engineering and parameter analysis . Intermetallics , 19 6 , 757 – 761 . doi: 10.1016/j.intermet.2010.11.014
   Google Scholar
• Beck , T. and Bostanjoglo , G. , 2010 . Producing a hole in a component such as a turbine blade, a combustion chamber lining or gas- or steam turbine by pulsed laser beams, comprises processing the laser beam over a surface of the component with the shorter laser pulse lengths . EP2168711-A2 .
   Google Scholar
• Bi , G.J. 2006 . Characterization of the process control for the direct laser metallic powder deposition . Surface & Coatings Technology , 201 ( 6 ) : 2676 – 2683 . doi: 10.1016/j.surfcoat.2006.05.006
   Web of Science ®Google Scholar
• Bi , G.J. 2007 . Development and qualification of a novel laser-cladding head with integrated sensors . International Journal of Machine Tools & Manufacture , 47 ( 3–4 ) : 555 – 561 . doi: 10.1016/j.ijmachtools.2006.05.010
   Web of Science ®Google Scholar
• Chan , W.K. 2003 . Rapid manufacturing techniques in the development of an axial blood pump impeller . Proceedings of the Institution of Mechanical Engineers, Part H: Journal of Engineering in Medicine , 217 ( 6 ) : 469 – 475 . doi: 10.1243/09544110360729108
   Google Scholar
• Cheah , C.M. 2005 . Rapid prototyping and tooling techniques: A review of applications for rapid investment casting . International Journal of Advanced Manufacturing Technology , 25 : 308 – 320 . doi: 10.1007/s00170-003-1840-6
   Web of Science ®Google Scholar
• Chen , X.J. 2011 . Analysis of ceramic shell cracking in stereolithography-based rapid casting of turbine blade . International Journal of Advanced Manufacturing Technology , 55 : 447 – 455 . doi: 10.1007/s00170-010-3064-x
   Web of Science ®Google Scholar
• Choi , J. , Dutta , B. , and Mazumder , J. , 2009 . Spatial control of crystal texture by laser DMD process . Supplemental Proceedings: Volume 1: Fabrication, Materials, Processing and Properties TMS (The Minerals, Metals & Materials Society) , 405 – 413 .
   Google Scholar
• Chua , C.K. 2005 . Rapid investment casting: Direct and indirect approaches via model maker II . International Journal of Advanced Manufacturing Technology , 25 ( 1–2 ) : 26 – 32 . doi: 10.1007/s00170-004-1865-5
   Web of Science ®Google Scholar
• Chua , C.K. , Liu , A. , and Leong , K.F. , 2010 . A practical approach on temperature variation in selective laser melting with a novel heat transfer model . Innovative Developments in Virtual and Physical Prototyping - Advanced Research in Virtual and Rapid Prototyping , 363 – 367 .
   Google Scholar
• Dai , H.J. , D'Souza , N. and Dong , H.B. 2011 . Grain selection in spiral selectors during investment casting of single-crystal turbine blades: Part I. Experimental investigation . Metallurgical and Material Transactions A: Physical Metallurgy and Materials Science , 42A ( 11 ) : 3430 – 3438 . doi: 10.1007/s11661-011-0760-6
   Google Scholar
• Das , S. 2000 . Direct laser fabrication of a gas turbine engine component (invited), Materials and Design, special issue on Rapid Prototyping . Rapid tooling and Solid Freeform Fabrication , 21 ( 2 )
   Google Scholar
• Glynn , S.V , Hlavaty , K.D , and Reed , G.M. , 2009 . Laser drilling process performing assembly for turbine blade of turbofan gas turbine engine, has fixture including fixture opening for receiving portion of turbine engine component, and non-metallic cover placed over portion of fixture . US2009211091-A1 .
   Google Scholar
• Goehler , J. , Kernstock , F. , and Rehme , O. , 2009 . The method for manufacturing a turbine blade through an additive manufacturing process and selective laser melting, comprises layer-wisely producing the turbine blade in which a first powder layer is locally melted by energy beam . DE102009048665-A1 .
   Google Scholar
• Halloran , J.W. 2011 . Photopolymerization of powder suspensions for shaping ceramics . Journal of the European Ceramic Society , 31 ( 14 ) : 2613 – 2619 . doi: 10.1016/j.jeurceramsoc.2010.12.003
   Google Scholar
• Jia , W.P. 2007 . Numerical simulation for temperature field of TC4 titanium alloy hollow blade during laser rapid forming process . Rare Metal Materials and Engineering , 36 ( 7 ) : 1193 – 1199 .
   Google Scholar
• Jiang , R.S. , Zhang , D.H. and Wang , W.H. 2010 . Research on the intelligent design system for investment casting die of aero-engine turbine blade based on knowledge . Journal of Aerospace Power , 25 ( 5 ) : 1061 – 1067 .
   Google Scholar
• Kumar , N. , Besant , C.B. and Ristic , M. 1988 . Process variables determining the dimensional and metallurgical properties of directionally solidified, cored turbine blades produced by investment casting of super-alloys . International Journal of Advanced Manufacturing Technology , 3 ( 2 ) : 3 – 19 . doi: 10.1007/BF02601608
   Google Scholar
• Lee , C.W. 2004 . Rapid investment casting: Direct and indirect approaches via fused deposition modelling . International Journal of Advanced Manufacturing Technology , 23 ( 1–2 ) : 93 – 101 .
   Web of Science ®Google Scholar
• Li , J.R. , Liu , S.Z. , and Yuan , H.L. Solidification simulation of investment castings of single crystal hollow turbine blade . Journal of Materials Science and Technology , 19 6 , 532 – 536 .
   Google Scholar
• Liu , W.N. , Zhang , L.F. and Hai , C. 2010 . Grain rate control of investment casting turbine blade with equaixed grain . Special Casting & Nonferrous Alloys , 30 ( 2 ) : 147 – 154 .
   Google Scholar
• Liu , Z. , et al. , 2011 . Silicon-based ceramic core used for directional hollow turbine blade and other precise casting fields, comprises quartz glass, cristobalite and zirconium oxide in specified amounts . CN102179477-A .
   Google Scholar
• Liu , Z.H. , et al. , 2012 . A preliminary investigation on selective laser melting of M2 high speed steel . Innovative Developments in Virtual and Physical Prototyping - Proceedings of the 5th International Conference on Advanced Research and Rapid Prototyping , 339 – 346 .
   Google Scholar
• Lu , Z.L. 2010 . The prediction of the building precision in the laser engineered net shaping process using advanced networks . Optics and Lasers in Engineering , 48 ( 5 ) : 519 – 525 . doi: 10.1016/j.optlaseng.2010.01.002
   Web of Science ®Google Scholar
• Lu , Z.L. 2011a . Investigation into the direct laser forming process of steam turbine blade . Optics and Lasers in Engineering , 49 ( 9–10 ) : 1101 – 1110 . doi: 10.1016/j.optlaseng.2011.05.016
   Web of Science ®Google Scholar
• Lu , Z.L. 2011b . Fabricating the steam turbine blade by direct laser forming . Materials and Manufacturing Processes , 26 : 879 – 885 . doi: 10.1080/10426914.2011.560225
   Web of Science ®Google Scholar
• Lu , Z.L. and Li , D.C. 2011 . Advanced manufacturing method of engine turbine blade of continuous fiber toughening SiC ceramics . Advanced Materials Research , 308–310 : 962 – 966 . doi: 10.4028/www.scientific.net/AMR.308-310.962
   Google Scholar
• Mann , B.S. , Arya , V. and Pant , B.K. 2011 . Influence of laser power on the hardening of Ti6Al4V low-pressure steam turbine blade material for enhancing water droplet erosion resistance . Journal of Materials Engineering and Performance , 20 ( 2 ) : 213 – 218 . doi: 10.1007/s11665-010-9656-7
   Google Scholar
• Mishra , S. and Ranjana , R. 2010 . Reverse solidification path methodology for dewaxing ceramic shells in investment casting process . Materials and Manufacturing Processes , 25 ( 12 ) : 1385 – 1388 . doi: 10.1080/10426914.2010.496125
   Web of Science ®Google Scholar
• Modukuru , S.C. , Ramakrishnan , N. and Sriramamurthy , A.M. 1996 . Determination of the die profile for the investment casting of aerofoil-shaped turbine blades using the finite-element method . Journal of Materials Processing Technology , 58 ( 2–3 ) : 223 – 226 . doi: 10.1016/0924-0136(95)02127-2
   Google Scholar
• Pi , G. 2011 . Research on the forming process of three-dimensional metal parts fabricated by laser direct metal forming . International Journal of Advanced Manufacturing Technology , 57 ( 9–12 ) : 841 – 847 . doi: 10.1007/s00170-011-3404-5
   Google Scholar
• Rashid , A. and Campbell , J. 2004 . Oxide defects in a vacuum investment-cast Ni-based turbine blade . Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science , 35A ( 7 ) : 2063 – 2071 . doi: 10.1007/s11661-004-0155-z
   Google Scholar
• Richter , K.-H. , 2008 . Laser material processing in the aero engine industry. Established, cutting-edge and emerging applications . Proceedings of the 3rd Pacific International Conference on Application of Lasers and Optics 2008 . MTU Aero Engines, D-80995 Munich , Germany , PIC2008_1005 , 1 – 6 .
   Google Scholar
• Shah , K. , Pinkerton , A.J. and Salman , A. 2010 . Effects of melt pool variables and process parameters in laser direct metal deposition of aerospace alloys . Materials and Manufacturing Processes , 25 ( 12 ) : 1372 – 1380 . doi: 10.1080/10426914.2010.480999
   Web of Science ®Google Scholar
• Shin , C.S. , Chen , B.L. and Cheng , J.R. 2010 . Impact response of a wind turbine blade measured by distributed FBG sensors . Materials and Manufacturing Processes , 25 ( 4 ) : 268 – 271 . doi: 10.1080/10426910903426448
   Web of Science ®Google Scholar
• Tian , J. , Xue , X.A. and Zhang , Y.B. 2003 . Numerical simulation and shrinkage defects prediction of a turbine blade investment casting . Journal of Materials Science and Technology , 19 ( 1 ) : 32 – 34 .
   Google Scholar
• Vaezi , M. , Safaeian , D. and Chua , C.K. 2011 . Gas turbine blade manufacturing by use of epoxy resin tooling and silicone rubber molding techniques . Rapid Prototyping Journal , 17 ( 2 ) : 107 – 115 . doi: 10.1108/13552541111113853
   Web of Science ®Google Scholar
• Wang , S. , Miranda , A.G. and Shih , C. 2010 . A study of investment casting with plastic patterns . Materials and Manufacturing Processes , 25 ( 12 ) : 1482 – 1488 . doi: 10.1080/10426914.2010.529585
   Web of Science ®Google Scholar
• Wu , H. 2009b . Rapid casting of hollow turbine blade using integral ceramic mold . Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , 223 ( 6 ) : 695 – 702 . doi: 10.1243/09544054JEM1366
   Google Scholar
• Wu , H. 2009c . Gelcasting of alumina based ceramic cores containing yttria for single crystal and directional solidification blades . Advances in Applied Ceramics , 108 ( 7 ) : 406 – 411 . doi: 10.1179/174367609X422045
   Web of Science ®Google Scholar
• Wu , H. 2011 . Improving High-temperature properties of alumina-based ceramic cores containing yttria by vacuum impregnating . Materials Science and Technology , 27 ( 4 ) : 823 – 828 . doi: 10.1179/026708309X12506933873062
   Web of Science ®Google Scholar
• Wu , H.H. 2009d . Rapid fabrication of alumina-based ceramic cores for gas turbine blades by stereolithography and gelcasting . Journal of Materials Processing Technology , 209 ( 18–19 ) : 5886 – 5891 . doi: 10.1016/j.jmatprotec.2009.07.002
   Google Scholar
• Wu , H.H. 2010 . Rapid casting of turbine blades with abnormal film cooling holes using integral ceramic casting molds . International Journal of Advanced Manufacturing Technology , 50 : 13 – 19 . doi: 10.1007/s00170-009-2502-0
   Google Scholar
• Wu , H.H. , Li , D.C. and Guo , N.N. 2009a . Fabrication of integral ceramic mold for investment casting of hollow turbine blade based on stereolithography . Rapid Prototyping Journal , 15 ( 4 ) : 232 – 237 . doi: 10.1108/13552540910979749
   Google Scholar
• Zhang , A.F. 2010 . Numerical simulation of powder flow field on coaxial powder nozzle in laser metal direct manufacturing . International Journal of Advanced Manufacturing Technology , 49 : 853 – 859 . doi: 10.1007/s00170-010-2657-8
   Google Scholar
• Zhang , A.F. 2011 . Influence of laser waveform features on accuracy of direct metal forming . Materials Technology , 26 ( 2 ) : 71 – 75 .
   Web of Science ®Google Scholar
• Zhang , D.H. , Jiang , R.S. and Li , J.L. 2011 . Cavity optimization for investment casting die of turbine blade based on reverse engineering . International Journal of Advanced Manufacturing Technology , 48 ( 9–12 ) : 839 – 846 .
   Google Scholar
• Zheng , X.H. , Tu , J.P. and Song , R.G. 2010 . Effects of temperature on microstructure and tribological performance of a-CNx films prepared by pulsed laser deposition . Materials and Manufacturing Processes , 25 ( 5 ) : 311 – 315 . doi: 10.1080/10426911003747980
   Web of Science ®Google Scholar
• Zhou , W.Z. , Li , D.C. and Chen , Z.W. 2011 . The influence of ingredients of silica suspensions and laser exposure on UV curing behaviour of aqueous ceramic suspensions in stereolithography . International Journal of Advanced Manufacturing Technology , 52 : 575 – 582 . doi: 10.1007/s00170-010-2746-8
   Web of Science ®Google Scholar
• Zhou , W.Z. , Li , D.C. and Wang , H. 2010 . A novel aqueous ceramic suspension for ceramic stereolithography . Rapid Prototyping Journal , 16 ( 1 ) : 29 – 35 . doi: 10.1108/13552541011011686
   Web of Science ®Google Scholar
• Zhu , G.X. 2011a . Numerical simulation of metallic powder flow in a coaxial nozzle in laser direct metal deposition . Optics and Laser Technology , 43 : 106 – 113 . doi: 10.1016/j.optlastec.2010.05.012
   Google Scholar
• Zhu , G.X. 2011b . The influence of standoff variations on the forming accuracy in laser direct metal deposition . Rapid Prototyping Journal , 17 ( 2 ) : 98 – 106 . doi: 10.1108/13552541111113844
   Web of Science ®Google Scholar
• Zhu , G.X. 2011c . Numerical simulation of thermal behavior during laser direct metal deposition . International Journal of Advanced Manufacturing Technology , 55 : 945 – 954 . doi: 10.1007/s00170-010-3142-0
   Google Scholar