Additively Manufactured Blisk with Optimized Microstructure for Small Turbine Engines
An integrally bladed rotor in which a hub and a web are formed from a fine grain microstructure using an investment casting process or from metal powder with a HIP process, and a plurality of rotor blades formed from a coarse grain microstructure using a metal additive manufacturing process, where the hub and the web and the rotor blades are formed as a single piece and from the same material.
We claim the following:
1 . An integrally bladed rotor comprising:
a hub;
a web formed outward of the hub;
a plurality of rotor blades extending outward from the web;
the hub and the web and the plurality of rotor blades all formed as a single piece;
the hub and the web being formed from a fine grain microstructure; and,
the rotor blades being formed from a coarse grain microstructure.
2 . The integrally bladed rotor of claim 1 , and further comprising:
an outer surface of the web being formed from a coarse grain microstructure the same as the plurality of rotor blades.
3 . The integrally bladed rotor of claim 1 , and further comprising:
the hub and the web and the plurality of rotor blades are all made from the same material but with different properties resulting from different grain structures.
4 . The integrally bladed rotor of claim 3 , and further comprising:
the material is a Low Solvus High Refractory material.
5 . The integrally bladed rotor of claim 3 , and further comprising:
the material is IN100.
6 . A method of forming an integrally bladed rotor, the integrally bladed rotor having a hub and a web and a plurality of rotor blades, the method comprising the steps of:
forming the hub and the web using an investment casting process or from metal powder with a HIP process; and,
forming an outer surface of the web and the rotor blades using a metal additive manufacturing process.
7 . The method of forming an integrally bladed rotor of claim 6 , and further comprising the step of:
forming the hub and the web and the rotor blades from the same material.
8 . The method of forming an integrally bladed rotor of claim 6 , and further comprising the steps of:
forming the hub and the web from a fine gain microstructure; and,
forming the rotor blades with a coarse grain and radially directional microstructure for high temperature resistance.
9 . The method of forming an integrally bladed rotor of claim 8 , and further comprising the step of:
forming an outer surface of the web with the coarse grain microstructure.
10 . The method of forming an integrally bladed rotor of claim 7 , and further comprising the step of:
Forming the hub and the web and the rotor blades from a Low Solvus High Refractory material.
11 . The method of forming an integrally bladed rotor of claim 7 , and further comprising the step of:
Forming the hub and the web and the rotor blades from IN100.