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The purpose of this paper is to present results of laboratory testing work on causes of a service failure/damage to an aircraft turbojet's gas‐turbine blade made of the EI 867‐WD alloy.

The tests comprised comparing the microstructure of a service‐damaged blade with microstructures of specimens drawn from a similar all‐new blade, both subjected to temperatures of different values for different annealing times.

Findings based on the comparison of experimentally gained results of microstructure examination of both the gas‐turbine blades were: the change in the microstructure of a damaged blade results from the growth and cuboidal‐to‐lamellar change of shape of the reinforcing phase γ′ (Ni₃Al); and the size and shape of this phase are comparable to those of the phase γ′ of a new blade subjected to annealing at temperature exceeding 1,223 K for 1 h. The results gained allowed for drawing the conclusion that the damaged turbine blade was operated in the exhaust‐gas temperature exceeding the maximum permissible value of 1,013 K for approximately 1 h in the course of an air mission.

The comparison‐oriented experimental testing work was carried out on a new blade manufactured in the way and from material identical to those of the damaged blade. The applied methodology enables us to gain qualitative results of investigating into the causes of a failure/damage to a gas‐turbine blade.

The presented methodology of identifying (origin‐finding of) a service‐induced damage to a gas‐turbine blade proves helpful in the case of an engine failure, when information on the operating conditions thereof is insufficient.

The paper is an original work by the authors. To the best of their knowledge, the issue has not been found in the literature, approached in this particular way. It has been based on research work on air accidents due to the service‐induced failures/damages to gas‐turbine blades in aircraft turbojet engines.

The purpose of this paper presents the effects of actively morphing root chord and taper on the energy of the flight control system (i.e. FCS).

Via regarding previously mentioned purposes, sophisticated and realistic helicopter models are benefitted to examine the energy of the FCS.

Helicopters having actively morphing blade root chord length and blade taper consume less control energy than the ones having one of or any of passively morphing blade root chord length and blade taper.

Actively morphing blade root chord length and blade taper can be used for cheaper helicopter operations.

The main originality of this paper is applying active morphing strategy on helicopter blade root chord and blade taper. In this paper, it is also found that using active morphing strategy on helicopter blade root chord and blade taper reasons less energy consumption than using either passively morphing blade root chord length plus blade taper or not any. This causes also less fuel consumption and green environment.

This paper presents a versatile and economical knowledge‐based assembly design of blade and shell assemblies by employing behavioral modeling concepts. Behavioral modeling is a new generation CAD concept aimed at achieving ultimately optimum results with the efforts made in the early stage of the product development cycle. As a result, the assembly process of any odd‐configured parts such as torque converter blades, can be accurately planned, and made adaptable to all potential in‐process alterations due to either changes of components design or that of the assembly kinematics. Optimum assembly design is achieved when the volumetric interference meets a desired value based on an expert's determination. Experimental verification of the proposed optimum assembly design conducted in Luk, Inc. with two different blades' assemblies demonstrates satisfactory results.

A MONG DESIGN CONCEPTS, the turbine‐blade is one of the most difficult to translate into accurate dimensional fact. Shape, often the material, the standard of accuracy that must be achieved, and, in a full manufacturing programme, the quantities that are required, all create not merely initial, but continuing problems. Blade production is, indeed, a complex and continuous exercise in quality‐control.

This paper presents experiment results that examine the validity of extracting blade vibration signature from the shaft torsional vibration signals. A special test rig was designed and manufactured for this objective. A set of strain gages were bonded to the shaft and to the blades to measure the shaft twisting and blade bending deformations respectively. A controlled frequency exciter excited the blade vibration. The shaft torsional and blade bending vibration signals were simultaneously recorded and presented in the time and frequency domains. The blade bending vibration frequencies appeared dominantly in the shaft torsional vibration signals for all blade vibration frequencies up to 100Hz. For frequencies higher than 100Hz, less sensitivity of the torsional vibration to blade vibration was observed.

Special probes were developed to test rotor blades for fatigue cracks. These probes utilize ultrasonic surface waves which are highly sensitive to fatigue cracks. The dimensions of the probes were kept small to make possible the testing of blades without the necessity of dismounting. The probes are built up from conventional commercial probes by attaching some small auxiliary equipment to them, which is very easy to manufacture. Searching blades with these probes is more reliable and less time‐consuming than with previously available methods.

The purpose of this paper is to validate mathematically the feasibility of extracting the rotating blades vibration condition from the shaft torsional vibration measurement.

A mathematical model is developed and simulated for extracting rotating blades vibration signatures from the shaft torsional vibration signals. The model simulates n‐blades attached to a rigid disk at setting angles and the shaft drives the disk is flexible in torsion. The model is developed using the multi‐body dynamics approach in conjunction with the Lagrangian dynamics. A three‐blade rotor system example is simulated for blades free and forced vibration under stationary and rotating conditions. Frequency spectrums for the shaft torsional and blades bending vibration are represented and studied for analysis verification purposes.

The torsional vibration frequency spectrums showed blades free and forced vibration signatures. The blade setting angle is shown to reduce the sensitivity of torsional vibration signal to blades vibration signatures as it increases. The torsional vibration signals captured the variation in blades properties and produced broadband frequency components for mistuned system. The shaft torsional rigidity is shown to reduce the sensitivity of torsional vibration signal to blades vibration if increased to extremely high values (approaching rigid shaft). The rotor inertia is shown to have less effect on the torsional vibration signals sensitivity. The method of torsional vibration as a tool for rotating blades vibration measurement, based on the proposed mathematical model and its simulation, is feasible.

There is a growing need for reliable predictive maintenance programs that in turn requires continuous development in methods for machinery health monitoring through vibration data collection and analysis. Turbo machinery and bladed assemblies like fans, marine propellers and wind turbine systems usually suffer from the problem of blades high vibration that is difficult to measure. The proposed new method for blades vibration measurement depends on the shaft torsional vibration signals and can be used also for verifying the signals from other types of bearings sensors for possible blades vibration condition monitoring.

This paper presents a unique mathematical model and simulation results for the rotating blades vibration monitoring. The developed model can be simulated for studying coupled blades vibration problems in the design stage as well as for condition monitoring in maintenance applications.

THE estimation of the stresses in airscrew blades presents difficult aerodynamic and structural problems, the solution of which often involves considerable labour even after simplifying assumptions have been made. The aerodynamic problems associated with airscrew design have received considerable attention and extensive wind tunnel tests have been made, but on the other hand, the literature on the elastic problems presented by the airscrew is nothing like as extensive, and is mainly concerned with the twisting of the blades and the frequencies of blade vibrations. There then appears to be some justification for taking the present opportunity to concentrate on the strength side of airscrew design, dcaliug especially with the blade bending stresses which arise. On this account methods of estimating the air loads on the blades will not be dealt with here, where it will be assumed that the distribution of the air loads on the blades is known.

The purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.

An experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.

Large deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.

When the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.