Development of Reverse Engineering Framework for Metallic Engine Parts: Case Study on a Titanium Based Fuel Pump Impeller and SS-304 Washer

Reproducing metallic components of an aircraft engine is a complex, resource intensive task, particularly when original CAD models and material specifications are unavailable. Reverse Engineering (RE) addresses these challenges by reconstructing the geometry and material properties of existing components, enabling independent reproduction and reducing reliance on Original Equipment Manufacturer (OEMs). This study developed and validated a parametric framework for RE by analyzing two metallic aircraft-engine components —a fuel-pump impeller and a star washer—representing different levels of geometric complexity. Point Cloud Data (PCD) were captured using a GOM Core 5.0 3D scanner and were processed in Geomagic Design X to generate parametric 3D models. The reconstructed CAD models were assessed for accuracy, with a deviation of ±63.7 microns, which falls within industry-accepted tolerances for such components. Material characterization was conducted using a combination of destructive and non-destructive techniques to assess microstructure, phase composition and elemental distribution. X-ray fluorescence (XRF), Laser-Induced Breakdown Spectroscopy (LIBS) and X-ray diffraction (XRD) were used to analyze the chemical and structural properties. Material analysis confirmed that the impeller was composed of Titanium Grade V alloy (Ti-6Al-4 V), while the star washer was stainless steel 304 (SS304). Hardness testing yielded values of 325.5 HV / 32.5 HRC / 304 HRB for the impeller, and 207 HV for the star washer. XRD analysis further revealed a face-centered cubic (FCC) crystal structure for the star washer —consistent with SS304—and a hexagonal close-packed (HCP) structure for Ti-6Al-4 V. This study identified viable manufacturing pathways, including subtractive and hybrid approaches, to ensure precise reproduction of the components. The structured framework developed in this research addresses spare part shortages by enabling indigenous, manufacturing, reducing reliance on OEMs, and enhancing maintenance efficiency in the aerospace industry, particularly in developing nations.