Turbine Blade

The wax and ceramic core process involves creating a wax mold of the blade, coating it with a ceramic shell, and then melting out the wax to leave a hollow mold that can be filled with molten metal.

The challenge
Achieving accurate shapes and forms, monitoring and extending the life of tools and dies, managing high-volume production, and dealing with process impurities.

Our solution
ZEISS solutions include advanced coordinate measuring machines (CMMs), optical measurement systems, specialized probes, and software that enable precise shape and form measurements, monitoring of tool/die wear, high-volume production, and detection of process impurities.

The metal casting process involves creating a mold and pouring molten metal into it. The metal is then allowed to cool and solidify within the mold before removal.

The challenge
Making sure that blade casting dimensions are accurate and carrying out non-destructive analysis for wall thickness measurements are the main challenges when operating in a harsh environment with large batches of blades.

Our solution
High-precision systems like CMMs and non-destructive analysis techniques like X-ray and CT scanning ensure precise measurements and structural integrity. Streamlined workflows and automation enhance the efficiency of processing large batches of blades in demanding manufacturing environments.

Advanced machining techniques are utilized to achieve the desired aerodynamic profile and dimensional accuracy for the blade.

The challenge
The machining process involves creating high-precision small features and tight tolerance root form features without damaging the material. Furthermore, efficient and reliable manufacturing processes are necessary for high-volume production while maintaining consistent quality and minimizing waste.

Our solution
Advanced metrology solutions such as coordinate measuring machines (CMMs) and optical measurement systems can provide precise and accurate measurements of the blade's dimensions, allowing for real-time feedback and adjustments to ensure the desired small features and tight tolerances are achieved during the machining process.

The coating process involves applying a protective layer onto the blade's surface to enhance durability, reduce corrosion, and improve overall performance.

The challenge
Ensuring uniformity and thickness of coating on turbine blades is a challenge. Furthermore, manual sampling inspection can be time-consuming and may not provide a comprehensive assessment, leading to potential quality issues or the need for rework.

Our solution
ZEISS microscopy systems can provide high-resolution imaging and analysis capabilities, allowing for precise examination of coating thickness and uniformity. Furthermore, ZEISS ScanBox and ATOS 5 for Airfoil are advanced optical 3D scanning systems that enable non-destructive inspection of the entire blade surface, ensuring accurate and efficient evaluation of coating quality.​

The turbine blade validation process involves extensive testing and analysis to ensure the blade can withstand high temperatures, pressures, and stress during operation.

The challenge
Challenges include the need for highly accurate measurement of intricate geometries, the capability to measure during manufacturing, and the requirement for non-destructive testing methods to ensure the structural integrity of the blades.

Our solution
ZEISS solutions include highly accurate coordinate measuring machines (CMMs) and computed tomography (CT) machinery designed for measuring complex geometries. In-process measurement systems for real-time monitoring during manufacturing and non-destructive testing solutions ensure the quality and structural integrity of the blades. Furthermore, ZEISS offers software solutions for data analysis and visualization, enabling efficient and accurate interpretation of measurement data.