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

theengineer.co.uk

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

#31

Post by cheeseprocedure »

fitzwatermellow wrote: post #25

Fantastic read! Now why can't all technical and scientific journalism hold itself to this standard? Instead of making the prevailing assumption that your average reader has the I.Q. of a parsnip and the scientific literacy of a kindergartener ;) Have always felt single-crystal foundaries could be a great driver for building low Earth orbit microgravity factories. There has been extensive research in the labs on ISS d…

"The Engineer" is a trade publication, so its writers have a very different target to hit than, say, those of a daily paper.

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

#33

Post by phasetransition »

filereaper wrote: post #9

On this topic, I'd like to ask how 3D printed parts fair in the new engines being built. [1] I'd love to hear about this from a Metallurgical Engineer or a Material Science Expert. [1] http://qz.com/667477/ge-fires-up-worlds-largest-commercial-j...

My graduate research was on a corner of the class of ceramic materials that are used as coatings on top of this type of turbine blades. Anything specifically you would like to know?

Generally, single crystal blades are designed for their resistance to creep at high temperatures. If your predominate creep mechanism is sliding at grain boundaries in a polycrystalline material, you can impart creep resistance by removing the grain boundaries. A single crystal is the limiting case of this process.

3D printed parts, so far, are polycrystalline, and would be used in other places in an engine's hot stage.

Happy to address specifics.

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

#35

Post by afterburner »

byebyetech wrote: post #8

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

Slightly nicer version:

https://www.youtube.com/watch?v=HWgDre-mSX4

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

#37

Post by Sophistifunk »

orf wrote: post #20
daemoncoder wrote: post #16

Earlier quoted context omitted.

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

There are more of these projects than you might think. Final Objective (a 55 Chev) is the best, IMO: http://www.australiastoughestcars.com.au/news/video-merlin-v...

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

#38

Post by cyberferret »

Always clearly remember when I was studying for my commercial pilot licence many years ago. In one class, an engineer took us for a tour of an airline hangar. He stopped in front of an engine on a rig and explained that EACH blade on the intake fan stage cost something like $40,000. That was about 4 times the price of the car I drove to that class!

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

#39

Post by johansch »

sspyder wrote: post #6

Not to take away from the engineering marvel that these parts and process represent, but the timing of this article is interesting - seems PR related. I recently read about problems ANA faced with Rolls Royce engines, specifically the turbine blades failing. There have been at least 3 incidents of engine failure, flights have been cancelled an all 787 engines have to be retrofitted with new blades. http://www.reuters…

Also don't forget the A380 RR disaster-that-was-prevented-by-sheer-luck.

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

#40

Post by userbinator »

cyberferret wrote: post #38

Always clearly remember when I was studying for my commercial pilot licence many years ago. In one class, an engineer took us for a tour of an airline hangar. He stopped in front of an engine on a rig and explained that EACH blade on the intake fan stage cost something like $40,000. That was about 4 times the price of the car I drove to that class!

In aviation, everything is extremely expensive due to the quality level required.
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