Search Results for aerospace engine components

Single crystal and directionally solidified casting processes are among the most complex techniques available, requiring stringent process control and a thorough understanding of engineered materials and specialty alloys. This article examines how an aerospace material company utilizes advanced investment casting techniques to create components that meet the increasingly demanding requirements of modern aerospace and gas turbine engines. The article highlights how solidification modeling and integrated computational materials engineering (ICME) have accelerated development processes by predicting material behaviors and optimizing casting parameters without extensive experimental testing.

During the past 30 years, enormous research has been devoted to developing titanium-base intermetallics for use in gas turbine engines as lightweight alternative to nickel-base superalloys. This article presents a brief history of Ti 2 AlNb and efforts to mature this material for commercial component production. The article includes processing experience insights gained from a current R&D program in China.

Laser shock peening is a novel surface engineering method that improves component performance by introducing deep compressive residual stress. It has demonstrated significant benefits in safety-critical applications such as aerospace engines. Ongoing research focuses on lowering the cost and increasing equipment flexibility.

Integrated computational materials engineering has proven effective in shrinking materials development timelines and accelerating the implementation of new materials in manufactured components. This article presents examples of aerospace alloys developed using ICME techniques and provides a glimpse of future applications.

Induction heating is used to produce high quality, reliable aerospace components as well as unique combinations of engineering characteristics.

Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.

Durable polyimide parts that can withstand challenging aerospace environments mean longer service life, less maintenance, and smaller part inventories for aircraft fleet owners.

Cold spray is an effective method of depositing a variety of temperature-sensitive materials in specialized applications, such as high-value aerospace component repair. The use of cold spray has seen a significant increase in the repair and restoration of housings for integrated drive generators used in commercial aircraft.

This case study reviews the considerations in using magnesium thermal spray surfacing to repair a hydraulic pump pad.

Forensic metallurgy investigations in archaeology and aerospace engineering follow similar technical protocols but serve different objectives. Archaeometallurgical analyses focus on artifact provenance and cultural heritage management with minimal invasive sampling, while aerospace investigations prioritize rapid failure analysis for operational problems. Four case studies illustrate the approaches: noninvasive macrophotographic analysis of an ancient silver cup revealed stress corrosion cracking, noninvasive investigation of a Boeing 747 accident identified fatigue failure in fuse pins due to inadequate load knowledge, invasive lead isotope analysis successfully provenanced Chinese bronzes using kernel density methods, and comprehensive testing of F-16 wing bolts ruled out hydrogen embrittlement. Both fields employ similar analytical techniques, including microscopy, fractography, and chemical analysis, but differ in sampling constraints, time pressures, and reporting goals, with successful investigations in both domains requiring interdisciplinary teamwork.

The extreme high-speed laser application (EHLA) process offers efficient deposition of high-performance materials in aerospace manufacturing, providing key advantages compared to conventional laser cladding. As a sustainable alternative to chrome plating, EHLA excels in material integrity, efficiency, and performance, while reducing costs compared to thermal spray and conventional laser cladding. This article discusses how EHLA can help to address many sustainability concerns within the manufacturing sector.

Ahead of formal certification, many advanced metals have been qualified for 3D printing, allowing for the creation of previously impossible aerospace parts including for the hypersonic environment.

For those who are active within the thermal spray industry, 2017 offered a dramatic mix of jubilation and concern over conditions within the global thermal spray market. This article briefly reviews some of the market factors influencing the industry in 2017 and future outlook.

Field assisted sintering technology (FAST) enables hybrid components for aerospace to be designed with reduced weight and without sacrificing performance. FAST can be used to produce metal, ceramic, and composite components with tailored properties via a powder metallurgy approach. In many cases, it is a one-step, cost-effective manufacturing process for production of net-shape components.

The unique metallurgy and microstructure of Cu-Ni-Sn spinodal alloys provide a combination of strength, toughness, hardness, and corrosion resistance, suiting them for applications ranging from bearings, bushings, and friction surfaces in all sorts of machinery to electrical connectors and EMI shielding gaskets.

Direct write technology is an innovative and economical materials deposition process that integrates conductive traces, antennas, circuits, and sensors onto components or embeds them within structures. The process has been in development since 2002 for use in aerospace, military, and energy markets. This article describes its use to print thermocouple sensors, heat flux sensors, heaters, conductors, and antenna patterns.

Vacuum plasma and low pressure plasma spray technologies each provide unique solutions for achieving superior properties in metallic coatings that require low oxide content and high density. Applications include various turbine engine components, as well as biomedical and electronics components.

Fabrication of aerospace components using additive manufacturing (AM) has matured to the point where part microstructures and mechanical properties compare well with those of conventionally produced material. This article looks at characteristics of AM methods, post-processing of AM parts, and AM part properties.

Fabrication of aerospace components using additive manufacturing (AM) has matured to the point where part microstructures and mechanical properties compare well with those of conventionally produced material. This article discusses the basics of AM, part design considerations, CAD models, and build and powder removal considerations.

Custom equipment designed for the deposition of exotic materials allows advanced coating solutions and ceramic matrix composites to be utilized for applications in automotive, aerospace, defense, energy, and the farthest reaches of space. This article describes custom systems for chemical vapor deposition and advanced materials processing.