Research and development of additive manufactured bladed disks
Abstract: The contemporary manufacturing methods for bladed disks, also known as \blisks",cause a great deal of material waste. To reduce the material waste and increasethe freedom of design, GKN Aerospace requested this project to evaluate additivemanufacturing (AM) as a manufacturing method for blisks. Additive manufacturingmethods were researched and evaluated based on mechanical properties, freedom ofdesign, material use, and production times. Finite Element Analyses with respectiverotation and pressures have been performed and reviewed. All researched methodshave been found to have the ability to fulfill the requirements by GKN Aerospace:Power Bed Fusion (PBF) methods and Direct Energy Deposition (DED) methods.This bachelor thesis is a collaboration between GKN Aerospace and students fromChalmers University of Technology and Pennsylvania State University. GKN Aerospaceprovided the project with CAD models on the current blisk design as well as dataabout loads and temperatures for the simulations. They also provided a list of parametersfor the design including restrictive safety standards and production times.GKN Aerospace stated that Titanium-64 (TiAl6V4) is the preferred metal alloy forproduction. A large part of the project was to examine and study different methodsof additive manufacturing in consideration for the production of blisks. The bestmethod was identified and specified to fit the needs of GKN Aerospace. The teamhad access to a running Gantt Chart scheduling tool to remain on task and ensurethat all parameters of the project were met throughout the semester long project.The team also stayed within the outlined budget, only spending $260.56 on traveland prototyping expenses.The main problem with contemporary additive manufacturing machines utilizingPBF are their relatively small size which led to researching joining techniques. Forthe DED methods researched, the main problem faced were geometric restrictionsin printing complex structures. After reviewing the objectives and comparing themusing a Pugh matrix, it was determined what concept would work best for GKNAerospace. Electron Beam Melting (EBM), a PFB method, should first be used toprint the blisk in sections. Then, the pieces should be joined together using ElectronBeam Welding (EBW). After this the blisk should be heat treated using HIPand finally machined to reach desirable surface textures. Further evaluation of themechanical properties of EBM TiAl6V4 and EBW will need to be done by GKNAerospace to ensure this design will work for this particular aerospace applicationshould they choose to move forward with this concept.Keywords: Additive Manufacturing, TiAl6V4, bladed disk, blisk, EBM, EBW
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