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2.1.6 Manufacturing Development for Silicon Nitride cT Components The purpose of this task was to initiate manufacturing development activities for the cT integral vane ring, and cT integrally bladed rotor. Both parts are somewhat larger than any parts previously produced by U.S. based silicon nitride manufacturers, and the integral vane ring presented a significant difference in component geometry from all previous U.S. ceramic turbine development efforts. The vast majority of the effort was conducted by Kyocera Industrial Ceramics Corporation in Vancouver, WA. Efforts in manufacturing development at Kyocera, for integrally bladed rotors, included a bisque machining study where 8 different bisque machining conditions were studied, and over 50 test panels were fabricated. Different material feed rates, tool spindle speeds, and cutting depths were evaluated for the bisque shaping process. UTRC provided the panels to ORNL for mechanical property analysis. These data were subsequently provided to Kyocera to provide them with feedback on the best tool conditions for blade fabrication. In addition, integrally bladed rotors were fabricated both with and without hand polishing of the bisque machined blade surfaces. The combined test data and manufacturing results from the integrally bladed rotors provided guidance to Kyocera for fabrication of integral vane rings. Vane ring blanks were pre-sintered and nitrided to prepare them for bisque machining. A CAM program was developed to enable machining of the complex vane ring geometry. The nitrided bisque-fired blanks were machined using a multi-axis ball end mill. Pictures of the vane ring after bisque machining of the airfoils are shown in Figure 2.1.31. 46PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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