Materials
A key limiting factor in early jet engines was the performance of the materials available for the hot section (combustor and turbine) of the engine. The need for better materials spurred much research in the field of alloys and manufacturing techniques, and that research resulted in a long list of new materials and methods that make modern gas turbines possible. One of the earliest of these was Nimonic, used in the British Whittle engines.
The development of superalloys in the 1940s and new processing methods such as vacuum induction melting in the 1950s greatly increased the temperature capability of turbine blades. Further processing methods like hot isostatic pressing improved the alloys used for turbine blades and increased turbine blade performance. Modern turbine blades often use nickel-based superalloys that incorporate chromium, cobalt, and rhenium.
Aside from alloy improvements, a major breakthrough was the development of directional solidification (DS) and single crystal (SC) production methods. These methods help greatly increase strength against fatigue and creep by aligning grain boundaries in one direction (DS) or by eliminating grain boundaries all together (SC).
Another major improvement to turbine blade material technology was the development of thermal barrier coatings (TBC). Where DS and SC developments improved creep and fatigue resistance, TBCs improved corrosion and oxidation resistance, both of which become greater concerns as temperatures increased. The first TBCs, applied in the 1970s, were aluminide coatings. Improved ceramic coatings became available in the 1980s. These coatings increased turbine blade capability by about 200°F (90°C). The coatings also improve blade life, almost doubling the life of turbine blades in some cases.
Most turbine blades are manufactured by investment casting (or lost-wax processing). This process involves making a precise negative die of the blade shape that is filled with wax to form the blade shape. If the blade is hollow (i.e., it has internal cooling passages), a ceramic core in the shape of the passage is inserted into the middle. The wax blade is coated with a heat resistant material to make a shell, and then that shell is filled with the blade alloy. This step can be more complicated for DS or SC materials, but the process is similar. If there is a ceramic core in the middle of the blade, it is dissolved in a solution that leaves the blade hollow. The blades are coated with the TBC they will have, and then cooling holes are machined as needed, creating a complete turbine blade.
Read more about this topic: Turbine Blade
Famous quotes containing the word materials:
“He was no specialist except in the relation of things.... He took most of his materials at second hand.... But no matter who mined the gold, the image and superscription are his.”
—Woodrow Wilson (1856–1924)
“Herein is the explanation of the analogies, which exist in all the arts. They are the re-appearance of one mind, working in many materials to many temporary ends. Raphael paints wisdom, Handel sings it, Phidias carves it, Shakspeare writes it, Wren builds it, Columbus sails it, Luther preaches it, Washington arms it, Watt mechanizes it. Painting was called “silent poetry,” and poetry “speaking painting.” The laws of each art are convertible into the laws of every other.”
—Ralph Waldo Emerson (1803–1882)
“If our entertainment culture seems debased and unsatisfying, the hope is that our children will create something of greater worth. But it is as if we expect them to create out of nothing, like God, for the encouragement of creativity is in the popular mind, opposed to instruction. There is little sense that creativity must grow out of tradition, even when it is critical of that tradition, and children are scarcely being given the materials on which their creativity could work”
—C. John Sommerville (20th century)