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APPLICATIONS FOR NEW CAD DESIGN AND OPTIMISATION TOOLS

Developing unique design capabilities whereby components can be re-designed for SLM, making use of AM design freedoms to reduce weight without sacrificing performance.

TITANIUM COMPRESSOR IMPELLER

The Hub, with industry partner Safran Power Units (SPU), has redesigned and optimised a Ti64 aero-engine compressor impeller for Selective Laser Melting (SLM). The redesigned and optimised SLM impeller demonstrated a weight saving of > 25%.

The reduced-weight impeller has successfully passed speed bench testing (at SPU), validating the stress modelling and design approach.

HYBRID STRUCTURED AERO ENGINE CONTAINMENT RING

In another collaboration with SPU, the Deakin team has created a novel hybrid sandwich structure designed to significantly reduce the weight of the aero engine containment rings (CRs). The structure consists of a woven carbon fibre ring sandwiched between an inner and an outer Inconel alloy ring made by SLM.

The rings were consolidated by welding and hot isostatic pressing (HIP) treatment at the Monash facilities.

This specially designed structure is expected to result in over 20% weight reduction of the component compared to the current part made of Inconel alloy. In addition to these two cases, numerous aero engine components have been designed and fabricated via AM for specific high-performance applications within SPU.

For example, the Hub fabricated the combustion chamber in three parts by SLM (compared to ~20 processing stages via traditional manufacturing). These three parts have been welded/brazed together, thus combining additive with traditional manufacturing to simplify the overall manufacturing process.