Development in Injection Molding Silicon Nitride Turbine Components

Abstract

The use of injection molding technology for the fabrication of near-net-shape silicon nitride turbine components has been demonstrated in a number of rotor and blade configurations. The current emphasis at GTE Laboratories is to refine the process, bringing it to a level of durability and reproducibility sufficient for production needs. Progress in injection molding technology development will be described with emphasis on the flow and mechanical property requirements for forming flaw-free green components. Application of the findings to the fabrication of AGT-5 axial turbine rotors and vanes under the DOE sponsored Advanced Turbine Technology Applications Project will be reviewed.

Development of Injection-Molded Gas Turbine Components: Investigation Into Toughening GTE PY6 Si3N4

“…As an example, a study was performed to identify a silicon nitride powder size distribution and binder formulation with improved resistance to the stresses generated during solidification and cooling of injection-molded components in the mold. 4 Other processing efforts are focused on process refinements and development of new techniques aimed at establishing a complete processing methodology capable of producing larger quantities of reliable engine components.…”