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project info
Start date: 1 April 2025
End date: 30 September 2028
funding
Fund: European Regional Development Fund (ERDF)
Total budget: 4 934 840,82 €
EU contribution: 2 325 906,24 € (53,95%)
programme
Programming period: 2021-2027
European Commission Topic
European Commission Topic

Development of an automated technology for the production of a new generation of coreed static turbine components of the low-pressure PW 1000 turbofan engine.

The subject of the project is the development of a new precision casting technology for a range of low-pressure turbine components that are an integral part of the new generation of aircraft engines from the PW1000 family, installed, among others, in Airbus A320neo aircraft. The aim of the project is to improve the previously used unit manufacturing processes geometrically complex and meeting the high operational requirements of six-blade castings of coreed machine segments through the implementation of industrial research and development works in relation to: - process design using numerical simulations, - production and quality control of coreed wax casting models and model kits, - production of multilayer ceramic molds, - melting and vacuum pouring using nickel superalloy, - core etching using a high-pressure autoclave, - grinding of castings using an automated machining station, - analysis of the microstructure and properties of castings, - quality control of castings using high-sensitivity FPI and X-ray technology. Individual changes of individual processes will be tested and verified as part of a demonstration series of castings and their comprehensive control. The proposed new approach to the implementation of complex processes of precise casting of six-leaf coreed segments of steering apparatus and, above all, the use of an automated machining station, using a 6-axis robot and optical scanners will allow to increase the reliability of individual production stages, and thus minimize the costs resulting from castings that do not meet the requirements of the MTU customer. As part of the project, an innovative technology for measuring, searching and machining foundry imperfections will be created. A digital twin of the robotic station will also be built, used to design, program and implement the developed solutions.

Flag of Poland  Rzeszowski, Poland