Business · Companies · 2 hrs ago
How single-crystal turbine blades withstand extreme heat and stress
Jet engines rely on turbine blades that face enormous mechanical stress and temperatures above 1,500C.
The blades are made by casting molten metal alloy and cooling it carefully so that one crystal forms through the blade instead of many small grains.
A spiral feature called a pigtail helps one crystal take over as the metal solidifies, and is cut off when the blade is finished.
Only a handful of companies can make these blades, and the process has been perfected in five countries, including the UK and US.
Their limited supply matters because demand is high and engine-makers depend on these critical parts.
In September, GE Aerospace announced an $11.75bn deal to acquire its turbine blade supplier, a move described as an effort to secure supply.
Rolls-Royce has also said it will invest more than £19m in its blade casting facility in Rotherham, while specialists continue to improve the technology and China seeks to prove its blades can match Western quality.
Jet-engine turbine blades can withstand mechanical stress and temperatures exceeding 1,500C.
The blades are made by carefully cooling molten metal alloy so it solidifies as a single crystal.
A small spiral called a pigtail helps one crystal take over as the metal cools.
Only a handful of companies can produce these blades, and the process has been perfected in five countries, including the US and UK.
Rolls-Royce and GE Aerospace have made separate moves related to blade production and supply.
- Who
- Rolls-Royce, GE Aerospace, Safran and other specialist companies produce single-crystal turbine blades.
- What
- The blades are grown from molten metal alloy and designed to withstand extreme heat and mechanical stress.
- When
- The casting method was developed during the 1960s. Rolls-Royce announced an investment in March, and GE Aerospace announced an acquisition in September.
- Where
- Rolls-Royce makes turbine blades in the UK, including at its Rotherham blade casting facility. The process is perfected in five countries, including the US and UK.
- Why
- Single-crystal construction helps blades withstand the conditions inside jet engines. The article says GE’s acquisition was described as an effort to secure supplies of critical components.
This story does not have two clearly opposing sides.
Engineers developed a method of casting molten alloy and cooling it carefully to form a single crystal.
Rolls-Royce said it would invest more than £19m in its Rotherham blade casting facility.
GE Aerospace announced it would acquire its turbine blade supplier for $11.75bn (£8.78bn).
- Temperature
- Exceeds 1,500C
- Production method
- Molten alloy is cooled gradually to form a single crystal
- Pigtail
- A small spiral that helps one crystal take over during solidification
- Countries
- The process has been perfected in five countries, including the US and UK
- Rolls-Royce investment
- More than £19m for its Rotherham blade casting facility
- GE Aerospace acquisition
- $11.75bn (£8.78bn) for its turbine blade supplier
What people are saying
It's about as complicated as manufacturing gets
fight the laws of the universe
Demand for [turbine blades] is huge.