Additive Manufactured Integrally Bladed Rotor Enters Second Phase
of Testing
PARIS–(BUSINESS WIRE)–Officials with the University of Notre Dame Turbomachinery Laboratory
(NDTL), Norsk Titanium (Norsk), Pratt & Whitney and TURBOCAM
International announce the continuation of testing of an additively
manufactured integrally bladed rotor (IBR). Building on initial testing
completed in 2018, this next phase of testing examines the dynamic
properties of the IBR. Manufactured using Norsk’s revolutionary Rapid
Plasma Deposition™ (RPD™) process, the IBR was inspected to the same
quality specifications used in Pratt & Whitney’s current turbomachinery
components.
The tests are being conducted at NDTL’s world-class turbomachinery test
facility in South Bend, Indiana. After completion of the initial
testing, where the IBR met 100% of all design, speed and pressure ratio
test points, the current test program looks at low and high cycle
fatigue characteristics of the IBR. Testing will include multiple
acceleration/deceleration cycles and investigate synchronous vibration
effects on the additively manufactured blades.
The testing was preceded by a manufacturing qualities evaluation
performed by TURBOCAM. The evaluation found no evidence of alpha case,
or residual stress concentrations, that would cause distortions
typically found in additive materials. Additionally, TURBOCAM confirmed
Norsk’s RPD™ material was well-suited to traditional milling operations,
and was as stable as Ti6-4 forgings.
The ultimate goal of this effort is to develop the manufacturing
specifications needed to deliver the complex, heavily-loaded components
for turbomachinery applications, while providing the cost and schedule
savings that have been proven on Ti 6-4 airframe components.
“Successful completion of this testing will show that additive materials
can be used in turbomachinery applications, and paves the way to a full
qualification effort,” said Norsk’s Chief Commercial Officer Chet Fuller.
The entire manufacturing and testing effort has been overseen by Pratt &
Whitney and is being evaluated for application to future engine
developments.
“Pratt & Whitney is excited to enter this next phase of testing.
Utilizing additive manufacturing techniques, such as Norsk’s Rapid
Plasma Deposition process, allows us to shorten the manufacturing and
development schedule for our critical turbomachinery components,” said
Chris Kmetz, vice president of Engineering, Module Centers, Pratt &
Whitney.
For more information on Norsk, visit www.norsktitanium.com.
Norsk will also have a display of its RPD™ technology, and the first
additive manufactured IBR, at the International Paris Airshow, June
17-20.
About Norsk Titanium AS
Norsk Titanium AS is the world’s pioneering supplier of aerospace-grade,
additive manufactured, structural titanium components. The company is
distinguished in the aviation industry by its patented Rapid Plasma
Deposition™ (RPD™) process that transforms titanium wire into complex
components suitable for structural and safety-critical applications.
Norsk Titanium is a tier-1 supplier to Boeing and is committed to
cost-reducing aerostructures and jet engines for the world’s premier
aerospace manufacturers. RPD™ is the world’s first FAA-approved,
3D-printed, structural titanium, delivering substantial lead-time and
cost savings for aerospace, defense, and commercial customers.
About the Notre Dame Turbomachinery Laboratory
The Notre Dame Turbomachinery Laboratory (NDTL) is a gas turbine
research and development facility supporting the major OEM’s in the
aerospace propulsion and power industries. NDTL works on the leading
edge of component aerodynamics, structural dynamics, instrumentation,
and computational methods. The NDTL team supports the transition of
advanced technologies required for the next-generation of gas-turbine
engines through early-stage research onto the products of its customers.
For more information, please visit turbo.nd.edu.
About Pratt & Whitney
Pratt & Whitney is a world leader in the design, manufacture and service
of aircraft and helicopter engines, and auxiliary power units. United
Technologies Corp., based in Farmington, Connecticut, provides
high-technology systems and services to the building and aerospace
industries. To learn more about UTC, visit its website at www.utc.com,
or follow the company on Twitter: @UTC.
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About TURBOCAM International
TURBOCAM is a recognized leader in turbomachinery with over 150
five-axis milling machines producing prototype and production parts in 4
countries. We offer our expertise in making integrally-bladed parts up
to 1100mm by five-axis milling and electro-chemical machining such as
aircraft engine blisks machined from solid forgings, axial and radial
impellers, turbines, compressors, turbochargers, and blades and vanes.
TURBOCAM’s strength in manufacturing software has helped make
prototyping a major emphasis of the company. We have produced thousands
of unique part designs and have grown into many areas of advanced part
development and production for aircraft engines under AS9100D
certification. We are also Nadcap® certified for aerospace coatings.
Contacts
Lauren Quesada, Griffin Communications Group
[email protected];
+1 281-744-7938
