Enabling Materials Processing Technology for Low-Cost Fabrication of Integral Bladed Rotors (IBR)

Keystone and Faraday, working with Large engine OEMs,IBR forging, and airfoil machining suppliers identified the highest cost drivers for the fabrication of IBR components for gas turbine engines for advanced aircraft systems. A Phase I project demonstrated the feasibility of reducing cost in two critical cost areas of IBR fabrication: the application of near-net shape forging methods for reduced raw material and machining, and selective material removal by the Faradayic process for the reduction or elimination of precision hand finishing, blending, and polishing required to finish the machined blades in today's baseline process. This Phase II project will mature these capabilities by conducting technical tasks in three areas: • Developing very near-net shape forging technologies to reduce raw material content, rough machining, and enable compatibility with the initial airfoil rough machining operations. • Developing selective material removal and automated polishing technologies that reduce or eliminate costly hand finishing operations to remove airfoil machining artifacts, applicable to both initial manufacture as well as IBR and blade repair. • Assess alternate fabrication and airfoil reconstruction approaches by applying wrought titanium deposition technologies currently under development. This Phase II project will be aligned with other propulsion initiatives.