Improving productivity and quality in high-temperature materials manufacturing

Engine components used in the high and low pressure sections of a turbine are made from materials such as high nickel-based super alloys, ceramic matrix composites (CMC), and/or intermetallics such as gamma titanium aluminide. Components are initially processed using casting, forging or sintering using powder metallurgy techniques and are subsequently turned over to traditional manufacturing processes such as milling, turning, broaching or grinding or non-traditional manufacturing processes such as Electro Discharge Machining (EDM), Electro Chemical Machining (ECM), laser machining etc. Since these materials are difficult-to-machine, due to their high strength, corrosion and fatigue resistance, and low thermal conductivity, increasing productivity often comes at the expense of decreasing quality or surface integrity of the manufactured component. This presentation will cover the grinding product technology and process techniques used to grind these materials at very high material removal rates while maintaining surface integrity and quality. Data from case studies in grinding of these specific high-temperature materials will be shown and tips to improve productivity will be shared.