Investment casting technology for production of TiAl low pressure turbine blades – Process engineering and parameter analysis

Low pressure turbine blades (LPT) made by investment casting from intermetallic titanium aluminide alloys for aero-engine applications in lengths between 200 and 400 mm require very demanding and sophisticated process for their manufacturing. Middle line shrinkage porosity along the airfoil and dimensional tolerances by near-net-shape casting are especially sensitive issues concerning Quality assurance. Nevertheless the urgency to manufacture safer environmental-friendly high performance aero-engines requires the introduction of new high performance components like LPT blades made of TiAl, which are about 50% lighter than their nickel-based counterparts. The present work is based on process engineering taking into account different melting and casting technologies in order to develop a dependable and reproducible series production route for TiAl LPT blades including the corresponding process parameter window.

► Near-net-shape investment casting of TiAl LPT blades for aero-engine application.
► Induction skull melting and casting of TiAl.
► Process validation for series production of aero-engine TiAl components.