Design and prototyping of a ceramic micro turbine: a case study

Abstract

Within the framework of the Collaborative Research Center 499 (SFB 499) of the German Research Foundation (DFG), one task was the development of a zirconia micro turbine as a demonstrator tool to enhance the interaction of the participating workgroups. This case study describes the evolution of the demonstrator and experiences gained with the design and the manufacturing of a micro device. Although it was not the aim of this basic research project to develop a commercial product, the experiences are valuable for improving the performance of industrial product development processes for ceramic micro devices. The various parts of the zirconia micro turbine were prepared by a rapid prototyping process chain (RPPC) that allows for a fast and inexpensive manufacturing of ceramic parts with details down to the micron range. A first design concept was made to mainly demonstrate the shaping feasibility of the process in the micro range. However, some features affected the performance due to their low loading capacity. Thus, a modified design was improved for power output and durability. After optimization of the process chain, dense and homogenous ceramic micro parts could be manufactured. These parts were used for the assembling of a functional micro turbine demonstrator, which was powered by compressed air.

Factors affecting strength and shape retention of zirconia micro bending bars during thermal debinding

“…Considering an increasing demand for customized ceramic micro parts and components [4], low-pressure injection moulding (LPIM), which is sometimes also referred as hot moulding [5], is a predestined fabrication method for prototypes and small series, as costeffective and re-useable moulds can be used [6,7]. By applying rapid prototyping process chain (RPPC) techniques [2,8], fast and inexpensive manufacturing of ceramic parts down to the micron range can be realized via LPIM, which was recently demonstrated in a successful case study on a ceramic micro turbine [9].…”

Elicitation of a reference process model for tool-based micro technologies for planning and controlling purposes and user support

“…The experience with the process chain was gained by only three exemplary integrated micro product engineering projects synthesizing the demonstration systems of SFB 499 (Albers et al 2006;Bauer et al 2009;Albers et al 2010a). Many single process steps (e.g.…”

Fabrication of Micro-Parts with High-Aspect Ratio Micro-Hole Array by Micro-Powder Injection Molding

“…With the rapid development of product miniaturization, the demand for micro-bearings, micro-cams, micro-holes, micro-gears, microscope heads, micro-tubes, micro-motors and other components is increasing [ 1 , 2 , 3 ]. As a typical widely used microstructure, micro-holes act as transfer and exchange media in the form of micro-channels or nozzles that can be used as fuel injection nozzles, spinnerets, jet turbine blade cooling holes, printer jets, fiber optic connections, micro-structures of an array hole in a micro-pump, and micro-hole structures in fiber optic connectors and biomedical filters [ 4 , 5 , 6 , 7 ].…”