Enabling Materials Processing Technology for Low-Cost Fabrication of Integral Bladed Rotors (IBR)

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-05-C-5307
Agency Tracking Number: F041-140-1422
Amount: $739,808.00
Phase: Phase II
Program: SBIR
Awards Year: 2005
Solicitation Year: 2004
Solicitation Topic Code: AF04-140
Solicitation Number: 2004.1
Small Business Information
1458 S. E. Ocean Lane, Port St. Lucie, FL, 34983
DUNS: 114133213
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Raymond Wallker
 Vice President
 (772) 878-1701
Business Contact
 Raymond Walker
Title: Vice President
Phone: (772) 878-1701
Email: raymwalk@aol.com
Research Institution
Keystone and Faraday, working with Large engine OEMs,IBR forging, and airfoil machining suppliers identified the highest cost drivers for the fabrication of IBR components for gas turbine engines for advanced aircraft systems. A Phase I project demonstrated the feasibility of reducing cost in two critical cost areas of IBR fabrication: the application of near-net shape forging methods for reduced raw material and machining, and selective material removal by the Faradayic process for the reduction or elimination of precision hand finishing, blending, and polishing required to finish the machined blades in today's baseline process. This Phase II project will mature these capabilities by conducting technical tasks in three areas: • Developing very near-net shape forging technologies to reduce raw material content, rough machining, and enable compatibility with the initial airfoil rough machining operations. • Developing selective material removal and automated polishing technologies that reduce or eliminate costly hand finishing operations to remove airfoil machining artifacts, applicable to both initial manufacture as well as IBR and blade repair. • Assess alternate fabrication and airfoil reconstruction approaches by applying wrought titanium deposition technologies currently under development. This Phase II project will be aligned with other propulsion initiatives.

* Information listed above is at the time of submission. *

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