AEROSPACE & DEFENCE

A Case Study in the Aerospace Industry

Title:
Crack-Free Superalloys for High-Performance Turbine Blades in Aerospace

Project Scope:

The project focuses on eliminating cracks in superalloy turbine blades during the Laser Powder Bed Fusion (LPBF) process, which are critical for high-performance aerospace applications. The goal is to tailor the microstructure by precisely controlling melt pool and solidification parameters, reducing the need for costly and ineffective post-processing methods like heat treatment and HIP.

Challenge:
Superalloys, commonly used in turbine blades, are highly susceptible to cracking during the LPBF process due to their complex thermal properties. Cracks compromise the structural integrity and performance of these components, which are vital for the aerospace industry. Traditional post-processing methods, such as heat treatment and Hot Isostatic Pressing (HIP), are expensive and often fail to remove all the cracks, leading to potential failures in service.

Solution:
OptiFab’s solution involves using advanced AI-driven control to manage the melt pool and solidification parameters during the LPBF process. By tailoring the microstructure in real-time, the process minimizes the formation of cracks and enhances the mechanical properties of the superalloys. This approach reduces reliance on expensive post-processing and improves the overall quality and reliability of turbine blades.

Expected Outcome:
1) Crack-Free Production: Achieve crack-free superalloy turbine blades directly from the LPBF process, eliminating the need for extensive post-processing.
2) Enhanced Mechanical Properties: Improve the mechanical strength and durability of turbine blades by tailoring the microstructure to withstand the extreme conditions in aerospace applications.
3) Cost Reduction: Significantly reduce production costs by minimizing or eliminating the need for post-processing methods like heat treatment and HIP.

Key Benefits of OptiFab’s Solution:
1) Melt Pool Control: Precise control over the melt pool and solidification parameters ensures crack-free production, enhancing part quality and reliability.
2) Microstructure Tailoring: Ability to tailor the microstructure in real-time, optimizing mechanical properties and reducing the risk of failure in service.
3) Cost Efficiency: Reduction in production costs by eliminating the need for costly and often ineffective post-processing techniques.

KPIs (Key Performance Indicators):
1) Crack-Free Rate: Target of achieving a 100% crack-free rate in superalloy turbine blades produced via LPBF.
2) Mechanical Property Improvement: Achieve a 30% increase in mechanical strength and durability in “as-printed” turbine blades.
3) Cost Savings: Reduce post-processing costs by 50%, with a goal of completely eliminating the need for HIP and heat treatment.

Additional Information:
This project demonstrates OptiFab’s capability to address one of the most critical challenges in aerospace manufacturing: producing high-performance turbine blades without cracks. By integrating AI-driven control with advanced microstructure engineering, OptiFab provides a solution that not only enhances the quality and performance of superalloys but also significantly reduces production costs, making it a valuable partner for the aerospace industry.

Note:
This case study is based on ongoing commercial discussions.