SAMULET II Project 7: Processing of High Temperature Materials

This project contains a variety of technology packages with the common goal of improving the capability to manufacture Turbine components from high temperature material. The project focussed on delivering a step change improvement in dimensional control of turbine blade manufacture through casting, using new ceramic material formulations with suitable low strength at solidification temperatures, which prevents defects and reduces scrap. The capability to fully adaptive machining solution for the finishing of turbine blades was advanced, with improved control of aerofoil shape and wall thickness. The shell characteristics for casting new titanium aluminide (TiAl) components have been evaluated. TiAl alloys offer a significant weight saving over nickel alloys, and their higher temperature capability supports more efficient high-temperature engines. The usable life of the ceramic slurry (a fluid mixture of the ceramic powder in solution) used in the casting process has been significantly increased, contributing to a 99% reduction in slurry lifecycle cost.

The collaboration with the University of Birmingham successfully developed an understanding of ceramic material properties and dimensional capability enabling the development of the next generation of casting ceramics, delivering improvements in wall thickness control of Single Crystal (SX) blade and static Turbine components.

Download the SAMULET II Project 7: Processing of High Temperature Materials case study
Short Title: SAM 2 P7
Project Number: 110106
Project Cost: £5,424,000
End Date: 31st Dec 2015
Time Horizon: Secure
Lead Partner: Rolls-Royce PLC
Attributes: Fuel Efficiency
ATI Value Stream: Propulsion of the future