The application of a lattice structure in the lightweight design of compressor impellers can reduce their mass and moment of inertia, hence improving the effective carrying of aircraft and reducing the start and braking moments of the impeller. The feasibility of a processing-lattice compressor impeller is the prerequisite for its application. To control the residual deformation and residual stress effectively, a computer-aided design technique is used to simulate the manufacturing process of a compressor impeller. The residual deformation and stress of the compressor impeller during the additive manufacturing process is calculated. The material-stacking process and base-plate- and support-removal process of a TiAl6V4 impeller printed by an SLM280 metal 3D printer are simulated by the finite-element method. The results show that some change in the laser printing parameters leads to a significant impact on the residual stress and deformation amplitude of the impeller. The residual deformation and residual stress of the lattice compressor impeller with the same geometrical appearance after processing are less than the corresponding amplitude of the solid compressor impeller, which also shows that the printed lattice compressor impeller can more easily achieve the design requirements.

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Taking the compressor impeller as the research object and the lightweight design as the research goal, a lattice filled lattice cell suitable for the application of rotating periodic symmetric structure is designed. Its purpose is to make the rigidity and strength of impeller adjustable and reduce the mass of impeller on the premise of meeting the design requirements. The analysis and comparison of unfilled impeller, solid impeller and lattice filled impeller with different diameters were carried out under the limit condition of 80,000 r/min. The results showed that the average circumferential deformation of lattice impeller tip with beam diameter of 0.2 mm, 0.4 mm and 1 mm was 4.84%, 3.49% and 3.71% lower than that of solid impeller. For the impeller with a lattice beam diameter of 0.4 mm, its weight can be reduced by 22.68% compared with the solid impeller. The average circumferential deformation of the tip of the lattice impeller lies between the unfilled impeller and the solid impeller. The results show that the impeller with lattice filling hub can not only reduce the weight effectively, but also improve the efficiency of the compressor.

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