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<p>The efficiency of a gas turbine engine is largely dependent on the high-temperature capability of its superalloy aerofoil components such as blades and vanes. These components are internally cooled by circulating cool air through their complex air channels. Conventional high-pressure turbine (HPT) blades have a single-wall cooling configuration wherein only one set of cooling channels in the component is utilized. To enhance the cooling efficiency of these blades, a novel design has been conceptualized in which the blade would have a double-wall cooling configuration by incorporation of an additional set of cooling channels. Fabrication of such single-crystal (SX) double-wall blades may not be possible through the conventional casting process alone because of certain practical difficulties. However, in the present feasibility study, an attempt has been made to cast the blade in multiple easy-to-cast SX parts and subsequently join them by the vacuum brazing method to realize the blade component. In this manufacturing method, it has been shown that it is feasible to realize three SX parts having identical &lt; 001 &gt; crystallographic orientation, which is necessary to produce a double-wall blade having the same orientation after joining the parts. It has been further demonstrated that the three parts can be joined by the vacuum brazing technique to realize the double-wall blade in which single crystallinity is maintained across the braze-joints.</p>

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Feasibility study on realizing single-crystal superalloy blades with double-wall configuration by a combination of vacuum investment casting and brazing methods

  • 期刊论文

  • 发表日期：

    2025年8月15日

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  • Alok Singh Chauhan,
  • Amit Kumar Singh,
  • Dibyendu Chatterjee,
  • Dipak Kumar Das

摘要

The efficiency of a gas turbine engine is largely dependent on the high-temperature capability of its superalloy aerofoil components such as blades and vanes. These components are internally cooled by circulating cool air through their complex air channels. Conventional high-pressure turbine (HPT) blades have a single-wall cooling configuration wherein only one set of cooling channels in the component is utilized. To enhance the cooling efficiency of these blades, a novel design has been conceptualized in which the blade would have a double-wall cooling configuration by incorporation of an additional set of cooling channels. Fabrication of such single-crystal (SX) double-wall blades may not be possible through the conventional casting process alone because of certain practical difficulties. However, in the present feasibility study, an attempt has been made to cast the blade in multiple easy-to-cast SX parts and subsequently join them by the vacuum brazing method to realize the blade component. In this manufacturing method, it has been shown that it is feasible to realize three SX parts having identical < 001 > crystallographic orientation, which is necessary to produce a double-wall blade having the same orientation after joining the parts. It has been further demonstrated that the three parts can be joined by the vacuum brazing technique to realize the double-wall blade in which single crystallinity is maintained across the braze-joints.