![]() In each of these processes, however, the surfaces have to be reworked, for example by automated polishing or by precise electrochemical machining PECM.Ī specially developed software made it possible to calculate the resource requirements of the different manufacturing process chains and technologies in a comparable way. To achieve an objective comparison, the research team looked at a few promising alternatives alongside conventional milling from a solid block: electrochemical machining ECM, water jet machining, and wire-based laser metal deposition, a manufacturing process for the layer-wise build-up of the blades. “We looked at a total of seven different process chains based on a Blisk made of nickel”, explained Daniel Heinen, manager of the business unit Turbomachinery at IPT. Researchers at the Fraunhofer Institute for Production Technology IPT in Aachen have compared different process chains from an economic and technological point of view – along with their colleagues from the tool machine laboratory WZL at RWTH Aachen and EMAG ECM GmbH. ![]() To ensure sustainable cost efficiency of manufacturing processes, the application potential of relevant technologies has to be monitored continuously and to be benchmarked in terms of productivity and manufacturing cost. Additionally the use of new materials requires continuous development of machining processes. Integrated design as established with the Blisk (blade integrated disk) in the past years leads to more complex geometries and manufacturing challenges. Using new technologies to realize innovative engine concepts allows manufacturers of aircraft engines to have a major influence on increasing resource efficiency in air transportation.
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