First developed in the 1960s, the casting technique uses a spiral mechanism called a pigtail to isolate and grow a single metallic grain from molten alloy. Because any secondary crystal formation ruins the component, manufacturers face exacting quality standards alongside intense global competition. To further endure operational flight stresses, the finished blades also incorporate specialized ceramic coatings and internal channels that route cooling air across their exterior surfaces.
Key points
Any formation of additional crystals during the cooling phase causes the blade to fail qu…: Any formation of additional crystals during the cooling phase causes the blade to fail quality checks, requiring the alloy to be reprocessed.
The advanced single-crystal components are vital for powering widebody jetliners such as…: The advanced single-crystal components are vital for powering widebody jetliners such as the Airbus A350-900 and Boeing 787.
Protective ceramic coatings and internal passages channeling cool air are required alongs…: Protective ceramic coatings and internal passages channeling cool air are required alongside the single-crystal structure to withstand temperatures topping 1,500C.
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Every time you fly, an extraordinary feat of endurance occurs inside the aircraft's engines.
Hidden from view inside the sleek outer nacelle are hundreds of little turbine blades that can shrug off enormous mechanical stresses and temperatures exceeding 1,500C.
It is a true engineering marvel. And these hardy blades are not sculpted or cut from their material – they are grown.
During the 1960s, engineers worked out how to take a molten metal alloy, cast it into the shape of a turbine blade, and then cool it very carefully from one end to the other over a matter of hours. A single crystal or grain of metal alloy forms during this process of gradual, delicate solidification.
Like turning a cup of water into one big snowflake, of your own design, rather than a mini blizzard of many smaller snowflakes.
"It's about as complicated as manufacturing gets," says Ben Fifoot, manufacturing engineer at Rolls-Royce, which makes turbine blades in the UK. "It's a real motivator to get out of bed in the morning."
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