Research Project "IDEAL"

(off.: Innovative Guss-/Schmiedetechniken für maßgeschneiderte Eigenschaften hochbelasteter TiAl-Niederdruckturbinenschaufeln)

Emissions reduction in aviation

Together with the aerospace industry, the European Commission has developed the research and innovation strategy »Flightpath 2050«. One of the goals of this strategy is an enormous reduction of CO2 and NOx emissions. Titanium aluminide has been identified as a key material due to its high-temperature properties combined with its very low weight. However, the processing of titanium aluminide (TiAl) is very challenging and is accompanied by a poor buy-to-fly ratio (weight of raw material to weight of finished part).

Process chain design of a flow production with machine integrated finishing strategy

»IDEAL« optimizes and tests production technology for cast TiAl low-pressure turbine blades on pilot plants. In order to achieve the expected production figures in industrial manufacturing, the existing production chain had to be further qualified and made more efficient.

In the project, the partners achieved a reduction in process times and costs through process chain and parameter optimization. For this purpose, a detailed planning of the process chain and investments was carried out using a dynamic process chain model and a cost calculation model. The process for mechanical finishing was also designed in detail with regard to the clamping concept, milling and grinding. In addition to the optimization of the parameters for machining, clamping options were investigated and a suitable variant was selected, and the process chain was optimized by layout and material flow planning. Finally, a structured procedure for companies was developed to meet the requirements of the EN 9100 quality management standard and thus facilitate certification. The certification of the project partner took place before the end of the project. Further research into the economic and technological competitiveness of TiAl investment casting is being conducted in the funded follow-up project NEXT.

Project Consortium

  • Leistritz Turbinentechnik GmbH
  • ACCESS e.V.
  • Fraunhofer Institute for Production Technology IPT

Project Management Organization

German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt e. V.)