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Applications of Green Technology in the Manufacture of Turbine Blades

This paper discusses the innovative use of ionic liquids in the manufacture and electropolishing of turbine blades. Ionic liquids, which are thermally stable and have low vapor pressure, offer unique solvent properties compared to traditional solvents. The study focuses on applications such as electropolishing of superalloys, providing enhanced surface finishes while minimizing environmental impact. Additionally, the recycling of spent electropolishing liquids is explored, promoting sustainability in manufacturing processes. Results indicate effective removal of surface contaminants and improved production efficiency.

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Applications of Green Technology in the Manufacture of Turbine Blades

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  1. Applications of Green Technology in the Manufacture of Turbine Blades Karl S. Ryder Scionix Laboratory, Department of Chemistry, University of Leicester, Leicester, LE1 7RH, UK k.s.ryder@le.ac.uk

  2. Contents • What is an ionic liquid • Eutectic-based ionic liquids and how to make them • Applications • Immersion Ag for PCB's • Cr plating • Al Plating • Battery applications • Electro polishing • RS Industrial Fellowship scheme • Results (RR3010 blades), XPS • Closing remarks

  3. Ionic liquids: definition • Ionic material that melts below 100 ºC • Unusual solvent properties • Very low / negligible vapour pressure - do not evaporate • Most liquids thermally stable >200 ºC • Immiscible with many organic solvents • Some have wide potential windows • Large and unsymmetrical ions -> low lattice energy and hence low melting point

  4. Historical perspective 1914 EtNH3+NO3- 1980’s Pyridinium eutectic with AlCl3 researched for Al deposition and Al batteries 1990’s Prevalence of imidazolium based cations 2000’s Environmentally more benign ionic liquids

  5. Liquid preparation • Just mix two components (often r.t. solids) to make liquid! • Endothermic reaction, entropy driven 10 ILs have been produced in over 200 kg batches One IL made on the tonne scale (for electropolishing)

  6. Electropolishing • Electrochemical dissolution: • ChCl / EG liquid • High current efficiency • Low toxicity • No strong acids • Comparable finish

  7. Electropolishing • Pilot plant • Functional process line • Pre treatment • Process, 50 L IL • Rinse Works very well for 300 series stainless steels and high value performance alloys, Ni / Co, Ti etc.

  8. Electropolishing • Better surface finish (market) • Non-corrosive (social) • Benign liquid – ChCl/glycol (social) • Improved current efficiency (>80%) (economic) • Less gas evolution (environmental) • Metal recoverable (environmental) • SS or Ti / IrO2 Cathodes • Ti Jigs • Standard pump / tank fittings • Less gassing • Better current efficiency

  9. Electropolishing • Royal Society Industry Fellowship (KSR) • Started July 2010: • Explore electropolishing of superalloys with IL processes • Study composition of alloy • Determine etch rate • Explore removal of scale (effect on surface melting) • Explore removal of casting shell

  10. Electropolishing • Strategy: • Polish metal • Vary conditions • Characterise surface • Heat treat

  11. Electropolishing; surface characterisation Electrolytic polishing in IL removes virtually all residual shell. First results suggest alloy composition is not effected by etch Surface roughness greatly reduced Electropolish Sample 1 (pale) Ni(3p)

  12. Electropolishing Partially immersed , polished blade (RR3010) 20 mins process time.

  13. Electropolishing Fully immersed , polished blade (RR3010) 60 mins, total process time. Eapp = 5.8 V

  14. Electropolishing Fully immersed , polished blade (RR3010) 60 mins, total process time. Eapp = 5.8 V Some trapped shell loosened!

  15. Electropolishing: recycling • Spent polishing liquid from the electropolishing process can be recycled and reused: • Spent liquid • Equal volume of water added • Settlement • Filtration • Heating (remove water) • Recylced liquid

  16. Conclusions • Electropolishing of superalloy turbine blades in DES type (choline chloride based) ionic liquids: • Effective in removing Ni-based surface scale • Effective in removing residual shell • Homogeneous dissolution of metal • Isotropic etching (semi-quantitative XPS) • Reducing surface roughness • Softening / loosening trapped shell • Visualising grain structure possible prior to heat treatment possible by electrolytic etch. This has the potential to save process time and reduce production costs. Hard back, 338 pages ISBN-10: 3-527-31565-9 ISBN-13: 978-3-527-31565-9 Wiley-VCH, Weinheim

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