Session: 18-07 Advanced Turbomachinery Manufacturing - Design, Materials & Processes

Paper Number: 83321

83321 - Fused Deposition Modeling Fabrication Evaluation of a Ti-6Al-4V Centrifugal Compressor 

Centrifugal compressors have a critical impact on the performance of a jet engine and made out of aluminum, steel, or titanium alloy, but if made out of Ti-6Al-4V it would be more lightweight than if steel were used and stronger than if aluminum were used. Compressors manufactured using traditional techniques can be relatively expensive to make, therefore, fused deposition modeling (FDM) or fused filament fabrication (FFF) can help reduce the cost while maintaining structural integrity. FDM/FFF usually prints polylactic acid (PLA) or acrylonitrile butadiene styrene (ABS) layer-by-layer using an extruder with a spool of material feeding into the extruder. Recently, metal-polymer filaments have become commercially available using this same printing apparatus as common "hobby-class" FDM printers. Using FDM with a metal-polymer matrix allows for a lower cost of production because of the intricate designs it can accomplish with little to no machining involved. Printing with Ti-6Al-4V is challenging because of the health concerns of the powder, but having the material in a spool eradicates these concerns of handling Ti-6Al-4V due to the Ti-6Al-4V powder being surrounded by a polymer. Even with the benefits of printing a spool of material using FDM, there has been very little research done of Ti-6Al-4V printed in a FDM format. Printing using the FDM process is known to create shrinkage of the part, it has been documented of different shrinkage percentages for steel using FDM but not Ti-6Al-4V. This document records the feasibility of using Ti-6Al-4V for a centrifugal compressor using FDM by incorporating a 3D structured blue light scanner before and after heat treatments while also analyzing shrinkage at the tips of blades as well as the base.

Presenting Author: Justin Warner ARCTOS Technology Solutions

Presenting Author Biography: Justin Warner is a contractor under ARCTOS Technology Solutions and works for the United States Air Force within the Aerospace Directorate. Having graduated with his Bachelor's degree from Wright State University in Dayton, Ohio and his Master's degree from The Ohio State University in Columbus, Ohio he strives to improving the techniques, capabilities, and quality of aerospace materials.

Authors:

Justin Warner ARCTOS Technology Solutions
Dino Celli Air Force Research Laboratory
Trevor Tomlin Air Force Research Laboratory
Onome Scott-Emuakpor Air Force Research Laboratory
Tommy George Air Force Research Laboratory