Turbine Unit

The production of the ceramic core and subsequent wax model requires tools to shape the ceramic material and tools to inject the wax that surrounds the core. The ceramic core serves as the internal cooling structure of the blade, while the wax model represents its external geometry.

The challenge

In order to obtain accurate shapes for the molds used in the production of the ceramic core and the wax model, the wear of the tools and molds must be monitored, and any irregularities must be corrected.

Our solution

A highly accurate tactile coordinate measuring machine (CMM) is used to inspect the critical features of tools and molds.

Meanwhile, advanced optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoils, provide full-surface measurements to assess tool condition. Portable measurement solutions allow tools to be measured on the shop floor.

Complete documentation of the entire production process is facilitated by PiWeb Reporting.

The ceramic core represents the inner cooling structure of the blade and vane, whereas the wax model represents the outer geometry of the blade. Prior to producing the wax model, the core is back-molded to achieve the final properties. To produce the wax model, the core is placed in the mold and after closing the mold, the wax is injected around the core.

The challenge

Achieving precise shapes for the ceramic core and wax model is essential. It is crucial to check the displacement of the core within the wax model to ensure minimum wall thickness of the blade after casting. Additionally, detecting imperfections in both the core and the wax model is vital for quality assurance.

Our solution

High-precision tactile CMM systems validate critical features for both tactile and non-contact measurements of parts.

Advanced optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoils, enable full surface measurements to monitor die conditions.

X-ray technology detects impurities or defects in wax or ceramic parts, allowing analysis in both 2D and 3D. This technology, combined with metrology, ensures minimum wall thickness.

Complete documentation throughout the production process is facilitated by PiWeb Reporting.

After the wax model (including the ceramic core) is manufactured, It will be arranged in a multiple part set up, to later on cast multiple parts with one shot. This set up is then covered with several layers of ceramic powder and liquid. The wax is melted out and leaves the actual casting mold (ceramic shell and ceramic core) behind. After another backing procedure, the shell is ready for casting and pouring in the molten metal.

The challenge

Ensuring the accurate displacement of the core within the ceramic shell is critical to achieving the minimum wall thickness of the blade after casting. Furthermore, it is essential to identify any imperfections in the shell, such as cracks or defects, that could compromise the integrity and performance of the final product.

Our solution

X-ray technology is utilized to detect impurities or defects within ceramic parts, allowing analysis in both 2D and 3D. When combined with metrology, this technology provides minimum wall thickness and accurate displacement detection.

Complete documentation throughout the manufacturing process is facilitated by PiWeb Reporting.

After casting, cooling and solidification, the ceramic shell and ceramic cores are removed. Once these are validated, the parts can be roughly machined or sent directly to the customer for further processing and finishing.

The challenge

It is important to ensure that the dimensions of the blade castings are accurate by validating the results, performing wall thickness measurements, detecting surface imperfections, and conducting quick measurements.

Our solution

Superior optical measurement systems such as the ZEISS Scan Box and the ATOS 5 for Airfoil are the solution for full surface measurements as they capture the entire surface.

It is also advisable to use high-precision CMM systems to measure the relevant areas of the root and profile.

With PiWeb Reporting, seamless integration into the workflow for processing batches within the production environment and complete documentation are possible.

The root of the turbine blade and the "socket" of the blade are precision machined to tight tolerances. Multiple parts are assembled in one step and must be perfectly aligned to meet the aerodynamic and dimensional requirements for optimum performance.

The challenge

Achieving accurate dimensions, meeting tight tolerances, and ensuring proper part fitment to counterparts are essential for optimal performance and quality.

Our solution

High-precision CMM systems ensure accurate and repeatable measurement results. They integrate seamlessly into the workflow, enabling efficient batch processing within the production environment.

Comprehensive documentation is maintained throughout the product lifecycle, with live feedback facilitating adjustments during production, all managed by PiWeb Reporting.

After the casting process, the blade and vane dimensions must be measured to ensure quality before the airfoil is machined. The final geometry and surface are created from the full-surface measurement and the actual data, before the coating process takes place.

The challenge

To identify scrap parts and ensure that components are properly sized for machining, accurate measurement of actual dimensions and airfoil geometry is essential. By providing critical data for machining airfoil geometry and surface features, these measurements enable precise guidance for machining equipment. In addition, assessing surface waviness and roughness is critical to meeting quality standards and improving the overall performance of the final product.

Our solution

Cutting-edge optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoils, offer thorough full surface measurements, providing critical surface data to coating machines. Alternatively, high-precision CMM systems can assess the pertinent sections of the airfoil.

These systems integrate smoothly into the workflow, allowing for efficient batch processing within the production environment. Comprehensive documentation is maintained throughout the product's lifecycle, with real-time feedback facilitating adjustments during production via PiWeb Reporting.

The coating process involves applying a protective layer to the surfaces of blades and vanes to enhance durability, reduce corrosion, and improve overall performance. The thermal barrier coating safeguards the components and ensures their longevity.

The challenge

Ensuring an even distribution of coating across the airfoil geometry of blades and vanes is essential. A minimum coating thickness must be maintained on each section, while coating quality, surface waviness, and roughness are critical factors. Additionally, the adhesion of the bond and individual layers, as well as coating thickness and quality, must be assessed at the microscopic level.

Our solution

Advanced optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoils, provide comprehensive full surface measurements, capturing essential data after the coating process. Alternatively, high-precision CMM systems can measure the relevant sections of the airfoil.

These systems integrate seamlessly into the workflow, facilitating efficient batch processing within the production environment. Comprehensive documentation is maintained throughout the product lifecycle, with real-time feedback enabling adjustments during production via PiWeb Reporting.

ZEISS Microscopy Solutions offer high-resolution imaging and analysis, allowing for precise examination of coating thickness and uniformity.

During the finishing process, the cooling holes are manufactured and opened to guide internal airflow through the blade, creating a protective layer during operation. This step involves opening and manufacturing the holes based on measurement results. Additionally, the final geometry of the root and frame is machined, and any coating residues are removed.

The challenge

Validating the final geometry across the airfoil of blades and vanes is essential. This includes determining dimensions for the final machining of cooling holes, as well as the frame and root geometry to collect offset data for precise machining. A final quality check and thorough documentation of quality are also required.

Our solution

Using advanced optical measurement systems, such as the ZEISS Scan Box and ATOS 5 for Airfoils, comprehensive full-surface measurements can be made, capturing essential surface information. Alternatively, high-precision CMM systems can measure the relevant sections of the root and airfoil.

These systems integrate seamlessly into the workflow, facilitating efficient batch processing within the production environment. Comprehensive documentation is maintained throughout the product lifecycle, with real-time feedback enabling in-production adjustments via PiWeb Reporting.

The inspection of turbine parts takes place on site and in overhaul facilities. Measuring the parts and gathering the actual data and condition of the geometry and coating itself is the primary goal of the inspection.

The challenge

Mobile systems are essential for on-site measurement, enabling the capture of full 3D data to assess the original geometry and condition of parts and coatings. Rapid measurement is crucial, as the rework process must commence quickly. Ensuring traceability of parts and their condition, along with providing feedback to R&D, is vital. Additionally, it is important to determine wear, identify coating thickness, and analyze the metal alloys used as a service company.

Our solution

State-of-the-art optical measurement systems such as the ZEISS Scan Box and ATOS 5 for Airfoils provide comprehensive full-surface measurements within production facilities. Additionally, mobile solutions such as the ATOS 5 for Airfoils, ZEISS ATOS LRX for large-volume parts and the handheld T-SCAN Hawk 2 are effective for blade and vane evaluation.

High-precision CMM systems are used to inspect critical areas of the blade root and vane socket. ZEISS Microscopy Solutions provide high-resolution imaging and analysis for accurate assessment of coating thickness and uniformity. An electron microscope can also be used to analyze the composition and quality of metal alloys to assist service companies in replacing parts.

End-to-end documentation throughout the production lifecycle ensures a feedback loop to R&D, facilitating improvements based on the data collected. PiWeb Reporting is the preferred solution for managing this process.

Once the parts pass the inspection process, the first step in the refurbishment location is to remove the coating using the sandblasting method. A subsequent inspection is necessary to collect accurate data, allowing the rework process to begin. Any missing tips or material will be welded onto the parts, followed by machining to achieve the final geometry.

The challenge

Capturing full 3D data is essential to determine the original geometry and condition of the parts. Rebuilding the geometry through reverse engineering is required to provide offset data for welding and machining. Accurate and rapid measurements are crucial for effective rework, as is mapping the coating thickness of the airfoil for recoating.

Our solution

For comprehensive in-situ full surface measurements, advanced optical measurement systems such as the ZEISS Scan Box and ATOS 5 for Airfoils are available. Mobile systems such as the ATOS 5 for Airfoils can also be used. ZEISS Reverse Engineering, combined with precise measurements, provides the offset data needed to reconstruct the original shape through welding and machining.

Critical areas of the blade root and blade socket are measured using high-precision CMM systems. Full documentation throughout the production lifecycle ensures a feedback loop to R&D, facilitating optimization based on the collected data. PiWeb Reporting is the preferred solution for managing this process.

The coating process involves applying a protective layer to the surfaces of blades and vanes to enhance durability, reduce corrosion, and improve overall performance. The thermal barrier coating safeguards the components and ensures their longevity.

The challenge

It is essential to ensure that the coating is evenly distributed across the airfoil geometry of the blades and vanes. A minimum coating thickness must be maintained on each section, while coating quality, surface waviness, and roughness are critical factors. Additionally, the adhesion of the bond and individual layers of the coating, as well as coating thickness and quality, must be assessed at the microscopic level.

Our solution

State-of-the-art optical measurement systems, including the ZEISS Scan Box and ATOS 5 for Airfoils, provide thorough, full-surface measurements that capture critical data after the coating process.

In addition, high-precision CMM systems can assess relevant sections of the airfoil.

The systems integrate seamlessly into the workflow, promoting efficient batch processing within the production environment. Detailed documentation is maintained throughout the product lifecycle, with immediate feedback allowing for adjustments during production via PiWeb Reporting.

Cooling holes must be accurately located and reopened during the finishing process. The perforations guide internal airflow through the blade, creating a protective layer during operation. In this step, the holes are opened and manufactured based on the measurement results. It also involves machining the final geometry of the root and frame and removing any coating residue.

The challenge

The validation of the final geometry over the entire airfoil of the blades and vanes is critical. Determining the dimensions for repositioning and reopening the cooling holes, as well as collecting offset data for final machining of the frame and root geometry, is essential. Thorough quality control and documentation of the results are also required.

Our solution

To precisely locate the cooling holes, optical measurement systems such as the ZEISS Scan Box and ATOS 5 for Airfoils provide comprehensive full-surface measurements. Otherwise, high-precision CMM systems can be used to measure the relevant sections of the root and airfoil.

The workflow of these systems is seamless, allowing for efficient batch processing in the production environment. Throughout the product lifecycle, complete documentation is maintained, with real-time feedback enabling adjustments during production via PiWeb Reporting.