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Turbine Blades

Turbine blades function in extreme thermal conditions, often above 1000°C, requiring materials with exceptional high-temperature performance. To meet these demands, single-crystal or directionally solidified nickel-based superalloys like CMSX-4, Rene 142, and Mar-M247 are employed.

Material Specification

Nickel-based Superalloy (Inconel 718, CMSX-4), Ti-6Al-4V (LP Turbine), or Ceramic Matrix Composite (CMC, SiC/SiC)

Aerofoil Geometry

Twisted/Lean Profile, Chord – 50–150mm, Aspect Ratio – 1.5–3.5, Leading/Trailing Edge Radii – 0.2–1.0mm

Root/Dovetail Design

Fir-tree (DIN 24911), Bulb-type, or Dovetail (GE E-class), Broached/Turned to ±0.01mm

Cooling Features

Multi-pass Serpentine Channels, Film Holes (Ø0.3–1.2mm, ±0.05mm), Transpiration Cooling (CMC Blades)

Surface Finish

Ra ≤ 0.8 µm (Aerofoil), Ra ≤ 1.6 µm (Root), EBM/SLM Finish (Additive Parts)
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Product Description

These alloys maintain mechanical strength at elevated temperatures through stable γ’ phase structures and optimized grain orientation. Precise control of solidification rates and crystal growth direction reduces creep deformation, ensuring durability and performance during prolonged high-temperature operation.

Coating Specification

Thermal Barrier Coating (TBC, YSZ 100–300µm), Aluminide (NiAl) Diffusion Coating, DLC (Leading Edge)

Fluid/Gas Compatibility

Profile Tolerance – ±0.05mm, Wall Thickness – ±0.1mm, Cooling Hole Position – ±0.03mm

NDT Requirements

X-ray (RT) for Internal Passages, Fluorescent Penetrant (FPI) for Surface Defects, CT Scan (Additive Parts)

Fatigue Life & Creep Resistance

LCF – 10⁴ Cycles @ 800°C, HCF – 10⁷ Cycles @ 500MPa, Creep Rupture – 1,000h @ 950°C/150MPa

Vibration Characteristics

1st Mode Natural Frequency – 500–1,500 Hz, Avoidance of Campbell Diagram Critical Zones

Technical Advantages

Surface degradation due to oxidation and hot corrosion significantly reduces blade life, especially under high sulfur or sodium-laden fuel conditions. Protective coatings such as MCrAlY systems, combined with ceramic thermal barrier coatings (TBCs), are applied using EB-PVD or plasma spray techniques. These coatings maintain adherence under thermal fatigue and offer long-term protection against corrosive gas compositions at turbine entry temperatures. 

Turbine efficiency relies on precise airfoil geometry for optimal aerodynamic performance. Manufacturing tolerance for chord length, camber, and twist angle is maintained within ±0.05 mm using multi-axis CNC machining and digital optical scanning. Airfoil surfaces are finished to controlled roughness levels (Ra < 1.2 µm) to reduce boundary layer separation. Consistency across batches is verified through coordinate measuring machines (CMMs) and digital comparator mapping. 

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Industry Applications

Aero Engine High-Pressure Turbines

Used in jet engines to extract energy from combustion gases for rotor drive, requiring high creep and thermal fatigue resistance.

Industrial Gas Turbines for Power Generation

Operate in base-load power plants to convert combustion energy into mechanical rotation with turbine blades exposed to continuous thermal cycling conditions. 

Steam Turbines in Thermal Power Plants

Transfer kinetic energy from high-pressure steam into shaft power; blade erosion and corrosion resistance are critical for prolonged performance. 

Turboshaft Engines for Helicopters

Convert high-temperature gas energy into shaft output for rotors; require low weight and high fatigue resistance under dynamic loading.

Marine Propulsion Turbines

Integrated into naval gas turbine engines for propulsion systems; demand resistance to salt-induced corrosion and sustained high-temperature performance. 

Combined Heat and Power (CHP) Turbines

Used for simultaneous electricity and heat generation in cogeneration systems; blades must handle variable loads and thermal transients reliably. 

 

Turbine Blades

Internal Cooling and Hollow Geometry Control

Thermal management through convective and film cooling requires complex internal channels with tight dimensional accuracy. Investment casting with ceramic cores enables formation of intricate serpentine passages, impingement cooling holes, and trailing edge discharge slots. Core shift and leaching processes are strictly controlled to maintain passage wall thickness within ±0.1 mm. 

Porosity, inclusions, and grain boundary phases compromise blade life under high-cycle fatigue conditions. Vacuum casting under inert atmosphere followed by hot isostatic pressing (HIP) is employed to eliminate micro-voids and restore density. Non-destructive evaluation methods, including radiographic testing, ultrasonic inspection, and metallographic sectioning, are performed on each batch. 

Turbine Blades

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Having Doubts? Our FAQ

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How does Frigate ensure consistency in cooling hole geometry across turbine blades batches?

Frigate uses precision ceramic core manufacturing with controlled shrinkage rates to maintain internal channel consistency. During casting, core alignment fixtures prevent shift and ensure repeatability. Post-casting, CT scanning verifies cooling hole placement and wall thickness. Airflow testing is also conducted to confirm that all holes meet design flow coefficients. 

What alloy systems does Frigate use for high-pressure turbine blades applications?

Frigate primarily uses nickel-based superalloys such as CMSX-4, Rene 142, and IN738 for their excellent high-temperature strength and oxidation resistance. Alloy selection depends on engine cycle temperature, required fatigue life, and creep resistance. Chemical composition is tightly controlled during vacuum melting to avoid inclusion formation. All alloy batches are certified per AMS or OEM-specific standards. 

 

How does Frigate control residual stress in turbine blades after casting?

Frigate applies thermal treatments including solution annealing and aging cycles to relieve internal stresses developed during solidification. Hot isostatic pressing (HIP) is used to close internal porosity and further equalize stress distribution. Final machining is performed under controlled parameters to avoid surface-induced stresses. Residual stress mapping is conducted using X-ray diffraction in critical zones. 

What quality systems does Frigate follow for turbine blade production?

Frigate operates under AS9100 quality management standards, with NADCAP-accredited processes for heat treatment, NDT, and coatings. Each blade is serialized and traceable through its full production route. Inspection data, alloy batch numbers, and process certifications are archived for audit readiness. Statistical process control (SPC) is used to monitor dimensional and metallurgical consistency. 

How does Frigate handle turbine blade tip grinding for tight clearance control?

Blade tip dimensions are ground using 5-axis CNC machines with in-process measurement systems. Frigate maintains radial tip clearance within ±0.02 mm to prevent rub during engine operation. Tip coatings, if applied, are ground back to final size after thermal spraying. Each blade undergoes rotor stack simulation to verify tip fit before dispatch. 

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LOCATIONS

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

Other Locations

  • Bhilai
  • Chennai
  • Texas, USA
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Turbine Blades

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