Compressor Wheels (turbojet/turbofan)

Name: Compressor Wheels (Turbojet/Turbofan) | Gas Turbine Compressor Rotor - Frigate
Price: 249.00 USD
Availability: InStock

Compressor wheels in turbojet and turbofan engines endure extreme centrifugal forces at rotational speeds above 60,000 RPM. Even minor geometric deviations in blade profiles or hub alignment can cause rotor imbalance, leading to vibration and fatigue failure.

Material Specification

Titanium 6Al-4V (Grade 5), Aluminum 2618A (Forged), or Inconel 718 (High-Temp)

Overall Diameter

Inducer – 50–300mm, Exducer – 30–250mm (Custom sizes ±0.05mm)

Blade Count & Geometry

15–45 Blades, Backswept (20°–40°), Aero-optimized (CFD-validated)

Hub/Bore Design

Tapered Bore (1:10/1:15), Spline/Keyway (SAE J498), H7 Tolerance (±0.018mm)

Balance Specification

G2.5 (ISO 1940-1), <0.1g·cm Imbalance, Trim Balancing Pads

Product Description

To ensure accuracy, these components are manufactured using precision 5-axis CNC machining combined with closed-loop dimensional control. This approach guarantees tight tolerances, optimal balance, and long-term reliability under high-speed operating conditions.

Surface Finish

Ra ≤ 0.4 µm (Blades), Ra ≤ 0.8 µm (Hub), Polished Leading Edges

Dimensional Tolerances

Blade Thickness: ±0.05mm, Tip Clearance: ±0.1mm, Runout ≤0.02mm TIR

NDT Requirements

FPI (Fluorescent Penetrant), Ultrasonic Testing (UT), X-ray (Porosity Check)

Fatigue Life & Burst Speed

LCF – 10⁵ Cycles @ 600°C, HCF – 10⁸ Cycles @ Yield Strength, Burst – 120% Max RPM

Vibration Characteristics

1st Mode – 800–3,000 Hz, Campbell Diagram Clearance

Technical Advantages

Compressor stages are subjected to repetitive thermal transients ranging from ambient to elevated operational temperatures near 900°C, particularly in multi-stage axial designs adjacent to combustor zones. Materials are selected based on their phase stability, oxidation resistance, and γ′ precipitate strengthening mechanisms. Nickel-based superalloys such as Inconel 713C, MAR-M247, and René-series alloys are deployed, often with controlled solidification and directional grain structures. Heat treatment cycles are defined to optimize creep resistance, thermal fatigue life, and phase homogeneity under sustained thermomechanical loads.

Compressor blade aerodynamics depend on maintaining boundary layer stability, minimizing flow separation, and reducing profile drag. Sub-optimal surface finishes, tooling marks, or micro-cracks induce turbulent flow, decreasing stage pressure ratio and isentropic efficiency. Surface treatments involve abrasive flow machining and micro-polishing to achieve surface roughness values below 0.2 µm Ra across both suction and pressure sides of the blade. Critical flow paths are evaluated using CFD-driven feedback loops to ensure compliance with designed Mach number distributions and incidence angle constraints.

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Industry Applications

Military Jet Engines

Used in afterburning turbojets for high-thrust propulsion under supersonic conditions with high-cycle fatigue and thermal stress tolerance.

Commercial Turbofan Engines

Supports bypass air compression in high-bypass-ratio engines for improved thrust-specific fuel consumption in civil aviation propulsion systems.

Unmanned Aerial Vehicles (UAVs)

Integrated in compact gas turbines for tactical UAVs requiring high power density with weight-optimized rotating components.

Auxiliary Power Units (APUs)

Installed in onboard gas turbine APUs to compress air for power generation and aircraft system startup functions.

Supersonic Research Platforms

Used in experimental engines for supersonic combustion and intake air compression across transonic and supersonic test flight regimes.

Industrial Gas Turbines for Power Generation

Employed in microturbines or aero-derivative turbines for compressing intake air in stationary power generation under continuous duty cycles.

Structural Soundness and Defect Elimination

Compressor wheels must operate without initiating crack propagation under Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) conditions. Sub-surface voids, inclusions, or dendritic segregation present in cast or forged blanks serve as initiation points for crack nucleation. Each component undergoes non-destructive testing including ultrasonic phased-array inspection, dye penetrant analysis, and radiographic evaluation.

Compressor wheels must conform precisely to application-specific aerodynamic and mechanical constraints, such as blade tip clearance, chord-to-span ratio, and hub-to-tip height gradient. Reverse-engineering workflows using 3D scanning and parametric modeling enable replication of legacy or foreign designs with full geometric and material traceability.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dynamic balance in high-RPM compressor wheels?

Frigate performs precision 5-axis machining followed by rotor-specific dynamic balancing using dual-plane correction techniques. Residual imbalance is reduced to below ISO G1.0 grade for aerospace-class rotors. Every wheel undergoes balance verification at simulated operational RPM. This ensures minimal vibration and extended bearing life in rotating assemblies.

What material certifications does Frigate provide for compressor wheel manufacturing?

Frigate sources aerospace-grade alloys with full traceability conforming to AMS, ASTM, and customer-specific standards. Each material batch includes mill test reports, ultrasonic inspection results, and chemical composition validation. Heat treatment cycles are documented with furnace charts and hardness verification. Certifications are archived digitally and available on request for audit compliance.

How does Frigate handle thin-wall airfoil machining without inducing distortion?

Frigate uses low-force cutting strategies with optimized toolpaths and adaptive feed control to avoid thermal distortion in blade sections. Fixturing systems are custom-designed to support trailing edges and suction surfaces during finishing. Real-time dimensional feedback is used to adjust tool paths dynamically. This ensures high geometric fidelity even on complex compressor blade profiles.

Can Frigate manufacture compressor wheels from forged billets instead of castings?

Yes, Frigate supports forged billet machining for applications requiring enhanced fatigue strength and directional grain flow. Closed-die forged blanks are pre-machined and then finished using high-precision CNC processes. Mechanical properties are validated through tensile, impact, and microstructure analysis. Forged wheels are typically used in high-load, high-reliability military and UAV engine programs.

What inspection protocols does Frigate follow for compressor wheel quality assurance?

Frigate applies multi-stage inspection including CMM-based dimensional checks, surface profilometry, and non-destructive testing (UT, DPI). All critical airfoil and bore dimensions are validated against CAD using automated probing systems. Surface roughness is measured across suction and pressure faces using contact and optical methods. Final inspection data is compiled into PPAP or FAIR formats as per aerospace requirements.

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Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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