International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025
p-ISSN: 2395-0072
www.irjet.net
A Comprehensive Comparison of Conventional and Additive Manufacturing in Jet Turbine Blade Production and Repair Anasuri Chanikya, Design Engineer Venkatareddy Chimalamarri, Senior Manager Cyient Ltd ---------------------------------------------------------------------***-------------------------------------------------------------------
Abstract - Turbine blades are vital in jet engines, enduring
Fusion (PBF) and Directed Energy Deposition (DED) are increasingly used for both blade production and repair, offering greater precision, design flexibility, and repair efficiency (Thompson et al., 5; Gong et al., 7).
extreme temperatures, stress, and rotational speeds. Traditionally, conventional manufacturing (CM) methods like casting, forging, and machining have been used for production and repair. However, additive manufacturing (AM) offers greater design flexibility, reduced waste, and faster repairs. This paper compares CM and AM in jet turbine blade production and repair, highlighting AM's advantages in creating complex geometries and enabling rapid, localized repairs. While CM remains dominant for large-scale production due to its reliability and cost efficiency, AM shows strong potential for low-volume, high-complexity aerospace applications. The study underscores the need for further AM material advancements, certification standards, and broader industry adoption.
2. CONVENTIONAL MANUFACTURING OF TURBINE BLADES Conventional manufacturing involves established techniques like casting, forging, and machining to shape materials into finished components. These methods are widely used across industries for their reliability, scalability, and ability to produce high-performance parts. Despite advancements in additive manufacturing, conventional techniques remain essential, especially in aerospace applications. Jet engine turbine blades operate under extreme conditions, requiring precise manufacturing for durability and efficiency. Conventional methods such as casting, forging, and machining offer specific advantages in material properties, geometric complexity, and production efficiency. This section examines these key processes in aerospace turbine blade manufacturing.
Key Words: Turbine blades, jet engines, conventional manufacturing, additive manufacturing, casting, forging, machining, design flexibility, reduced waste, rapid repair, complex geometries, aerospace applications.
1.INTRODUCTION
2.1 Casting
Turbine blades are critical components in the aerospace industry, particularly in jet engines, where they operate under extreme temperatures, pressure, and mechanical stress. Their performance directly affects engine efficiency, reliability, and fuel consumption (Kollu, 1). Therefore, turbine blades must be manufactured with exceptional precision, durability, and material integrity to ensure safe and efficient flight operations (Sińczak et al., 2). Traditionally, jet turbine blades have been produced using conventional manufacturing (CM) methods such as casting, forging, and machining. While reliable, these techniques often result in high material waste, longer production times, and limited design flexibility (Sun et al., 3; Wang et al., 4). Repairing damaged blades with CM processes, including welding and brazing, is labour-intensive and costly, especially for localized repairs (Brice et al., 12).
Casting is a formative manufacturing process where molten metal is poured into pre-formed molds, allowing it to solidify into the desired shape. This method is widely used for jet turbine blade production due to its ability to create near-net shapes in large volumes. It is particularly advantageous for producing complex blade geometries with internal cooling channels that are essential for withstanding high temperatures and mechanical stresses inside jet engines. Process Steps:
In recent years, additive manufacturing (AM) has emerged as a transformative technology in aerospace production and repair. AM, or 3D printing, enables the fabrication of complex geometries, reduces material waste, and accelerates repair processes (DebRoy et al., 6). Techniques such as Powder Bed
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Wax Model Creation: The process begins with the creation of a wax model, which represents the turbine blade shape. The wax model is injected into a master mold to form the cooling passages by surrounding ceramic cores. Pinning wires are inserted to secure the ceramic core throughout the process (Kollu, 1). Mold Preparation: The wax models are assembled into clusters, and multiple layers of ceramic slurries (alumina, silica, zirconium) are applied to form the
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