Advanced metal transfer additive manufacturing of high temperature turbine blades

During the pursuit of this research, a novel method for the additive manufacture of metal parts has been developed. To this end, a way to create the complex geometrical structure of Inconel 625 jet turbine blades has been engineered. This advanced hybrid PETG and 90% Inconel 625 powder has first been Additive Manufactured into the shape of a turbine blade. The resulting green part produced was initially debinded at a temperature of 350 °C followed by heating to a sintering temperature of 1350 °C. This resulted in the transformation of a part into a solid Inconel 625 structure, which was later tested to understand the microstructural and mechanical properties of the material. It was found that although there was a slight degree of porosity, the structures were still mechanically sound, up to a temperature of 600 °C. The turbine blades were later machined to high tolerance 0.2 µm finish surface as is required for such components. This novel means for the fabrication of such complex and ultimately expensive to create structures allows a revolution in manufacture capabilities through the use of 3D Metal transfer printing technology.