COMPRESSOR & TURBINE AEROFOILS

Adaptive Machining for Compressor and Turbine Aerofoils

Our blade Adaptive Machining solutions offer extreme versatility and can be used on a wide range of components from both hot and cold sections of the engine. Typical applications include the manufacture and repair of compressor and turbine components.

Repair (MRO) Applications: -

Our Adaptive Machining solutions are used by many of the world’s leading MRO organisations to automate a wide range of repair processes including: -

HPC, IPC blade tip re-contouring .:

HPC, IPC blade tip re-contouring
  • Fully Hands-free operation
  • Rapid cycle times (as low as 2 minutes)
  • Very high accuracy (+0,00 / +0,02mm) or better

HPC, IPC Chord Restoration .:

HPC, IPC Chord Restoration
  • Re-profiling of L/E + T/E profiles
  • Reduced repair time per part
  • Tightly controlled edge geometry
  • Elliptical (or user-defined) edges

HPT Tip Restoration .:

Hands free re-contouring of aerofoils following weld repairs
  • Any size and type of blade catered for
  • High-precision outer profile re-contouring
  • Inner (squealer) profile accurately modelled and machined
  • Fast, reliable and efficient

3-D “End-Bend” Compressor Blades .:

3-D End-Bend Compressor Blades
  • Complex “3-D” aerofoil geometry handled automatically
  • Aerofoils such as 535-E4 and CFM56-7
  • Minimum programming and process development time
  • Ultimate software-based process control

Cluster Vanes .:

Cluster Vanes
  • All inner & outer rails machined in 1 set-up
  • Adaptive Fixtures taking single & multiple span components
  • Unique “Process-selector” user-interface
  • Ultimate software-based process control

Aerofoil Patch Machining (Turbine Buckets) .:

Aerofoil Patch Machining (Turbine Buckets)
  • Stress crack removal
  • Efficient machining of tough nickel-based alloys
  • Zero step between parent and new material
  • Extending the life of expensive components

Features & Benefits

  • Very low cycle times
  • Completely hands free operation
  • Virtually net finish (zero step)
  • Quick Return on investment
  • All blade types catered for (inc. 3-D “End-Bends”, Squealers, etc)

New Part Manufacturing Applications: -

Nickel based turbine blade 5-axis machined from solid

Our experience in manufacturing new Gas Turbine components includes:

  • Milling & Grinding of HPT & HPC root and shroud forms
  • Elliptical Leading edge machining
  • LP compressor Snubbers (mid-span shrouds).
  • Blending of platform surfaces onto aerofoils (& vice-versa)
  • Closed loop feedback
  • Automatic flash removal from castings and forgings

In all our applications, 3, 4 and 5-axis machining strategies are fully supported in order to provide the ultimate in process efficiency & flexibility. As a result, our Adaptive Blade Machining Solutions offer the lowest cycle times and the highest levels of quality and accuracy available – and this means the quickest return on investment.

  • Precision Machining from Forgings and Bar Stock
  • Optimised 5-axis machining strategies
  • Many machine tools supported
  • Adaptive Machining optimises accuracy between root & shroud
    and gas path surfaces
  • Lowest cycle times and consumable costs

 

A StarragHeckert group company