ZEISS AEROSPACE SOLUTIONS

Compressor Blade

Achieving efficiency in engine design

Aircraft engine compressors have thousands of blades, each 25 – 200 mm. As modern compressor blade designs create thinner and more twisted airfoils, the bar for precision continues to rise.

Even the tiniest imperfection on the surface or a variation in the profile of a compressor blade or vane can adversely affect airflow, impair blade performance and lower engine efficiency. Global production of these components reaches millions annually, with a corresponding high volume of returns for maintenance, repair, and overhaul (MRO). Hence, having precise measurement and inspection solutions is essential for ensuring a seamless production process.

ZEISS compressor blade solutions throughout the entire production process

Quality is a vital aspect of the manufacturing process for compressor blades. With millions of parts produced each year and very short cycle times, the risk of significant non-conformances is high without careful monitoring. ZEISS quality solutions, a key asset for our aerospace customers, enable the placement of the right equipment on the shopfloor at the point of manufacture. They also provide real-time feedback using software tools, precisely where it's most beneficial, ensuring immediate corrective actions.

Click through all process steps

Forging process

It’s incredible how modern machinery and software analysis can profoundly impact traditional processes like forging, leading to significant improvements in productivity and the rate of accurate results.

The challenge
Ensuring the die and subsequent blades are conforming is a critical task, and ZEISS technologies play a pivotal role in this process.

Our solution
ZEISS technologies are great for digitally capturing and analyzing in 2D and 3D the conformity of the blades and the life and wear of the die.

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Milling rough shape

Given the forging's variability, rough milling the blade before final blade machining is a critical part of the process!

The challenge
Rough milling is a fast process in harsh conditions, leaving a similar challenge for measurement and inspection.

Our solution
Within the ZEISS technology range, shopfloor equipment is designed to meet the speed requirements and handle challenging environments on the shopfloor.

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Final machining

The airfoil edges with the proper radii for performance, the root form for fit to the compressor disc, and the airfoil tip to ensure no leakage of compressed gas.

The challenge
Final machining is a swift process with small tolerances on many critical features and demands the efficiency of a high-end solution like ZEISS PRISMO fortis.

Our solution
ZEISS PRISMO fortis is the go-to machine for meeting the challenges of the final machined compressor blade.

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Validation

Ensuring compliance with regulatory and OEM standards, such as AS9102 or AS13003, is necessary and imperative. Our solution is designed to help you fulfill these stringent and comprehensive requirements.

The challenge
The compressor blade has an extensive set of validation requirements to demonstrate airworthiness.

Our solution

High-accuracy tactile, optical, and microscopy solutions to fulfill thousands of characteristics necessary to validate.
ZEISS Quality Suite helps to compile the results effectively.
Specific software like ZEISS INSPECT Airfoil enables the efficient qualification of every characteristic on part drawings or other standards.

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Maintenance, repair, and overhaul (MRO)

Increase service and maintenance intervals

Once the engine is in operation, it will undergo regular inspection and maintenance. As airlines aim to increase the intervals between each maintenance visit, modern 3D metrology can help MRO shops extend the compressor blades' life or reduce the time required for each service visit.

A compressor blade is susceptible to a wide range of defects, each presenting a unique challenge. These defects can manifest in different blade zones (A, B, C), on different sides of the airfoil (convex or concave), and on different types of edges (leading or trailing). They include undersize chord, reduced thickness, and roughening of the blade surface, among others.

Dimension faults