Engineered for performance
A bladed disk, also called a ‘blisk’ or integrated blade rotor (IBR), consists of blades machined into a rotor disk to form a single part. Bladed disks are mainly used in high-pressure compressors, and increasingly in low pressure compressors including the fan blades. Newer bladed disk designs include so-called ‘blums’: a combination of several bladed disks on a drum with multiple stages. Measuring bladed rotors is highly complicated due to their exotic sizes, shapes and special machining techniques, including unique combinations to achieve the desired characteristics. However, ZEISS solutions can meet all these demands.
Quality Gates along the Blisk Production Process
The processes for manufacturing blisks are a high investment and long while the desired speed for measurement is as short as possible. This clash in circumstances puts stress on manufacturers to produce high-quality blisk products at a speed that keeps up with the ever-increasing demand of the aerospace market. Our customers are increasingly opting to choose ZEISS solutions to deliver the fast, reliable and repeatable results in minutes rather than hours.
Billet or Forging disc
The blisk starts as a raw material, forged hub and sometimes individual airfoils.
The interity of the raw material is critical to the the final product. The material, composition and purity must be checked. In the case of forgings the material shape has to be measured for conformity.
- ZEISS Industrial Microscopy solutions are the perfect compliment to the production of raw materials, checking their metallurgical composition
- ZEISS ScanBox offers full field measurement and inspection for forgings
Disc and Hub Machining
Creating the interface and weight relief features for the compressor blisk is a high-accuracy activity.
Measuring precision bores, as well as weight relief grooves which may not have direct access in an accurate and timely manner.
- For high-accuracy needs the ZEISS PRISMO Family is perfect. The integrated rotary table reduces measuring cycle times significantly
- For the surface finish ZEISS ROTOS sensors can accurately determine roughness
Linear Friction Welding
The process of adding pre-forged blades to the disc hub body by means of mechanical rubbing is a common technique which has specific quality requirements.
Inherently of a welding process, there is excess material at the position between the root of the airfoil as it connects to the disc which necessitates further machining.
- ATOS ScanBox is the only way to ensure a flawless blend and transition between the airfoil and the annulus surface on the blisk is to measure the data in 3D and pass data to third party adaptive machining processes.
Whether it's full machining from stock material, or blending a linear friction welded airfoil, the airfoil machining is a very time consuming process which has huge importance to the performance of the engine.
The airfoil geometries are getting more and more complex, more twisted and sharper edges, factory floor space is at a premium, and production rates are high demanding faster measurement times.
- ZEISS solutions are fast, accurate, optical and tactile solutions which are compact to meet the demands of our customers. Whether the solution is tactile scanning or 3D data capture, the answer is a ZEISS solution.
Regulatory and OEM requirements like AS9102 or AS13003 are necessary, stringent and comprehensive to fulfil.
There are extensive validation requirements on a blisk with complimentary solutions needed to fulfil all requirements.
- High-accuracy tactile, optical and microscopy solutions to fulfil thousands of characteristics necessary to validate
- ZEISS Quality Suite helps to compile the results in an effective way
- Specific software like Blade Inspect Pro enables to qualify every characteristic on part drawings or other standards in an efficient manner