Feature Article
Leveraging Ceramic Additive Manufacturing to Produce Low-Cost Advanced Turbine Engine Castings
by Dan Z. Sokol, Renaissance Services Inc. Abstract T
here is a growing need for cast turbine engine components that can be delivered rapidly and
affordably. For example, traditional tooling
for castings is proven to be
durable for thousands of applications, but the lead time and non-recurring cost are prohibitive for an engine program that needs a few development castings or requires more complex castings. Renaissance
Services has led a
program to develop various advanced methods that leverage additively manufactured tooling to enable the low- cost production of conventional and advanced castings for turbine engines. The program focuses on multiple tooling options for the optimal solution to address overall cost, lead time, and technical capabilities.
concepts combine 3D-printing of ceramic
molds, wax patterns,
The tooling and
injection dies. Most importantly, the tooling approaches have enabled the low-cost production of advanced turbine castings that previously have been extremely difficult and expensive to produce. These include compressor sections that combine multiple rows of airfoils into a single casting; as well as a cooled integrally vaned stator with cast- in cooling holes.
Introduction A historical challenge for the Department of Defense is rapid development and deployment of new systems to meet evolving and emerging threats.
In
recent years, a critical element in the new systems equation has focused on small, unmanned aircraft.
Investment
castings are still considered as critical to the cost and performance of the small and medium-sized turbine engines for
28 ❘ August 2023 ®
Figure 1: Traditional Investment Casting Process With Multiple Steps
Figure 2: 3D-Printed Ceramic Molds On Printing Platform
these systems. Essential turbine engine components, produced from castings, impact cost, lead time, and performance. A key driver for these castings is the
tooling used to produce them. A growing need exists for engine component parts that can be delivered rapidly, affordably, and in both small
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