The rotor/stator castings consist of a central hub (shrouded in some designs) over which a number of aerofoil shaped blades are located. In recent times, such engines are also used for strategic missile applications. Traditionally, these turbines are used as starter engines. Modern turbine engines for aerospace applications need precision investment cast components such as integrally cast rotors and stators, for their hot end turbine stages. Present paper attempts to highlight issues related to tooling for ceramic cores for development of a near-net shaped, Ni-based Superalloy Dual Property HIP Rotors. In a recent effort, tooling for ceramic cores have been successfully developed to produce complex shaped rotors for space application using powder metallurgy techniques. This application of investment casting technology has been well established in DMRL. In advanced aero-engine applications, the hot end components of the turbine stage consisting of blade/vane castings have extremely complex internal geometry generated using the ceramic cores. To meet stringent dimensional requirements, the tool geometry has to be precisely compensated for shrinkage and distortion phenomenon observed in the entire process of the component development. Development of tooling to precisely and accurately shape the ceramic core using Ceramic Injection Moulding (CIM) method is of primary concern.
Ceramic cores are used as sacrificial inserts to generate intricate and complex hollow shapes in components made of advanced materials for aero-engine and aerospace applications.
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