A novel technique for the manufacture of moulds for turbine blades

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Welch10EngD.pdf

2030-07-01 accepted http://eprints.org/relation/hasVolatileVersion http://etheses.bham.ac.uk/id/document/43736 http://eprints.org/relation/hasVersion http://etheses.bham.ac.uk/id/document/43736 http://eprints.org/relation/hassmallThumbnailVersion http://etheses.bham.ac.uk/id/document/43736 http://eprints.org/relation/hasVolatileVersion http://etheses.bham.ac.uk/id/document/43737 http://eprints.org/relation/hasVersion http://etheses.bham.ac.uk/id/document/43737 http://eprints.org/relation/haspreviewThumbnailVersion http://etheses.bham.ac.uk/id/document/43737 http://eprints.org/relation/hasVolatileVersion http://etheses.bham.ac.uk/id/document/43738 http://eprints.org/relation/hasVersion http://etheses.bham.ac.uk/id/document/43738 http://eprints.org/relation/hasIndexCodesVersion http://etheses.bham.ac.uk/id/document/43738 43736 2 105290 document 43736 small.png image/png ba3ff1fa5ce1cebd4312a79a8964db96 MD5 5041 2015-08-06 17:58:56 http://etheses.bham.ac.uk//id/eprint/774/6/small.png 774 6 6 image/png thumbnail_small Thumbnail Documents conversion from application/pdf to thumbnail_small en staffonly

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http://eprints.org/relation/isVersionOf http://etheses.bham.ac.uk/id/document/43444 http://eprints.org/relation/isVolatileVersionOf http://etheses.bham.ac.uk/id/document/43444 http://eprints.org/relation/isIndexCodesVersionOf http://etheses.bham.ac.uk/id/document/43444 archive 4031 disk0/00/00/07/74 2015-07-14 09:54:23 2019-01-23 09:52:49 2015-07-14 09:54:23 thesis show 0 Welch Stewart T Blackburn Stuart ftp://ubira.bham.ac.uk/eTheses/774_Welch/ University of Birmingham Rolls-Royce plc A novel technique for the manufacture of moulds for turbine blades unpub TS 10col_ephy Full embargo until July 2015 then option C until July 2030. A novel process in which turbine blade moulds are manufactured by rapid prototyping has been developed. Fine control over the raw materials and their processing is required. The non- Newtonian rheological behaviour of the ceramic slurries can be modified through changes in the dispersant levels. A link between dispersant concentration, particle-particle interactions and firing performance has been suggested. Alumina agglomerates that remain through mixing were identified and shown to affect the viscosity of the resin by as much as 30% leading to poor process robustness. X-ray tomography was used to identify and visualise highly orientated defect structure in the ceramic linked to the layered build and the residual stress distribution developed by the Gaussian profile of the laser. It was shown that changes to the laser settings would affect the structure of defects but did not allow for defect removal. The flexural strength of the ceramic produced was found to be by highly dependent on sample orientation and varied between 14 and 52 MPa. Methods to improve the defect structure were explored, including changes in UV cure technology, changes in process settings, removal of agglomerates from the alumina and improved firing schedules. Both a reduction in defects and improved surface finish were identified. It is apparent that moulds suitable for casting applications can be processed using this novel technique. 2010-07-13 2009-10 graduation eng author unchecked This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. Rolls-Royce restricted 305 University of Birmingham School of Chemical Engineering d_en na 2010-07-13 graduation