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Rolls-Royce’s single-crystal turbine blade casting foundry

theengineer.co.uk

11–20 of 75 posts

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#11

This is the best documentary on how RR makes the jet engine and the blades. 1 hour long but once you click it, it would be hard to stop! https://youtu.be/VfomloUg2Gw

I agree also wanted to post it when I saw the article. Absolutely mesmerizing to watch.

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#12
post #5

This was a super fun read, and it felt nice to take the time to carefully read it to understand the very complex processes it was describing. That said, can someone explain how the pigtail accomplishes the following?: > "The crystals grow in a straight line in the direction that the mould is being withdrawn, but because of the pigtail’s twisted shape, all but the fastest-growing crystals are eliminated."

By the principle of elimination by bottleneck. As the crystals grow into the pigtail, the lagging crystals hit the already-formed leading ones or the mold surface, leaving a primary, single crystal grain to exit the pigtail and grow across the blade proper. This would be almost impossible to happen without the pigtail because multiple crystal grains would grow in parallel across the blade.

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#13
I had the chance recently to see the Mayor of the City of London's (the strange city-within-a-city bit of London) two Rolls Royce's they keep for formal occasions up close. They are super rare (only ~400 ever made), worth a whole lot of money and looked amazing.

I'm not a car person but you can't help but feel a shiver when you see a car like that. The engines where the same as the ones they used in the Spitfire fighter planes during WW2 (6.5 liter v8!), full white leather interior, a retractable partition between the passengers and the chauffeur.

I know this isn't strictly about the article but I thought I would share anyway. Rolls is one of the things that makes me proud to be British.

Here's a picture: http://c8.alamy.com/comp/C1ETKT/city-of-london-lord-mayors-o...

Edit: It's a Phantom VI - https://en.wikipedia.org/wiki/Rolls-Royce_Phantom_VI, and the first article on Google is unfortunately this: http://www.dailymail.co.uk/news/article-1165522/Lord-Mayor-L...

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#15
post #5

This was a super fun read, and it felt nice to take the time to carefully read it to understand the very complex processes it was describing. That said, can someone explain how the pigtail accomplishes the following?: > "The crystals grow in a straight line in the direction that the mould is being withdrawn, but because of the pigtail’s twisted shape, all but the fastest-growing crystals are eliminated."

A helix functions as a grain selector. I think that only the crystal with axial alignment is fastest in general at propagating through a spiral.

Animation of the effect: https://www.youtube.com/watch?v=br9iaeYYxSM

Paper on the development of single crystal casting: http://www.tms.org/superalloys/10.7449/2008/Superalloys_2008...

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#16
post #13

I had the chance recently to see the Mayor of the City of London's (the strange city-within-a-city bit of London) two Rolls Royce's they keep for formal occasions up close. They are super rare (only ~400 ever made), worth a whole lot of money and looked amazing . I'm not a car person but you can't help but feel a shiver when you see a car like that. The engines where the same as the ones they used in the Spitfire fig…

Spitfires used v12's, not V8's.

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#17
post #5

This was a super fun read, and it felt nice to take the time to carefully read it to understand the very complex processes it was describing. That said, can someone explain how the pigtail accomplishes the following?: > "The crystals grow in a straight line in the direction that the mould is being withdrawn, but because of the pigtail’s twisted shape, all but the fastest-growing crystals are eliminated."

I don't fully understand the process, but this paper has an explanation and diagrams: http://www.journalamme.org/papers_vol32_1/32110.pdf

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#19

This is the best documentary on how RR makes the jet engine and the blades. 1 hour long but once you click it, it would be hard to stop! https://youtu.be/VfomloUg2Gw

If you liked that documentary, you might love this older one, which features Stanley Hooker. It's amazing to get the perspective of the legendary engineer himself, and it goes much more in depth into the technical problems and business challenges.

https://www.youtube.com/watch?v=by4lH2whhjk

Re: Rolls-Royce’s single-crystal turbine blade casting foundry

#20
post #13

I had the chance recently to see the Mayor of the City of London's (the strange city-within-a-city bit of London) two Rolls Royce's they keep for formal occasions up close. They are super rare (only ~400 ever made), worth a whole lot of money and looked amazing . I'm not a car person but you can't help but feel a shiver when you see a car like that. The engines where the same as the ones they used in the Spitfire fig…

Spitfires used v12's, not V8's.

Ahh, shame, you're right. They where 27 litre as well! That would be a bit extreme. Seems someone was silly enough to put it in a car though: https://www.youtube.com/watch?v=u43pWEwI6xY
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