Table of Contents:
- Introduction to Aero Engine Blade Inspection
- The Challenge: Moving Beyond Conventional Methods
- The Solution: Introducing Blazer 2S Flex
- Implementation: From Trial to Full Production
- The Impact: Driving Efficiency and Accuracy
- Expanding Horizons: Future Scalability and Adoption
- Conclusion: The Future of Blade Inspection
Introduction to Aero Engine Blade Inspection
In aerospace manufacturing, precision isn’t just a goal—it’s a necessity. Minor deviations in aero engine blade geometry at the root, shroud, platform, or fillet radii can significantly affect engine performance, fuel consumption, and reliability.
Historically, manufacturers relied on inspection tools such as comparators, go-no-go gauges, and mechanical CMM probes. While these methods served their purpose, they introduced subjectivity, slowed production, and failed to fully capture the complexity of modern aero engine blade geometries.
To address these limitations, MTL 3D collaborated with a prominent turbine blade manufacturer. The objective was clear—automate the inspection process, enhance accuracy, and reduce inspection times, ensuring each blade meets the highest quality standards consistently.
The Challenge: Moving Beyond Conventional Methods
The inspection of critical turbine blade features has long relied on outdated and labor-intensive methods, including:
- Industrial Comparators – Effective for basic geometry analysis but prone to subjective operator interpretation.
- Go-No-Go Gauges – Binary pass/fail tools that lack detailed dimensional data.
- Conventional CMM (Mechanical Probe) – Accurate but slow, with limited access to intricate features.
- Visual Inspection – Limited to external features, leaving room for undetected deviations.
Key Challenges Faced by Manufacturers:
- Subjective Results – Operator experience heavily influences inspection outcomes.
- Extended Cycle Times – Manual inspections take 30 to 35 minutes per blade.
- Limited Access – Probes fail to inspect tight areas like fillet radii and breaking edges effectively.
To enhance efficiency, the manufacturer sought an automated, non-contact solution capable of handling the intricate geometries typical of aero engine blades.
The Solution: Introducing Blazer 2S Flex
MTL 3D developed the Blazer 2S Flex—a six-axis, non-contact inspection system specifically engineered to tackle the complexities of turbine blade geometries. Building on the proven Blazer 2S platform, the Flex model introduces enhanced automation, greater adaptability, and faster inspection cycles.
Key Features of Blazer 2S Flex:
- Six-Axis Non-Contact Scanning – Provides full coverage of intricate and hard-to-reach areas.
- Automated Inspection – Reduces operator dependency and eliminates subjective variability.
- Retrofit Compatibility – Older Blazer 2S models can be upgraded to meet evolving inspection needs.
- Real-Time Reporting – Data is fed directly into quality control workflows, expediting corrective actions.
Comparison of Blazer 2S Flex with Conventional Methods:
| Inspection Area | Blazer 2S Flex | Conventional Methods |
|---|---|---|
| Root | ⏱️ (Long Cycle) | |
| Shroud | ⏱️ | |
| Platforms | ⏱️ | |
| Fillet Radii | ❌ (Limited Access) | |
| Breaking Edges | ❌ (Visual Only) |
By adopting Blazer 2S Flex, manufacturers can reduce inspection time while expanding the coverage of critical aero engine blade features.
Implementation: From Trial to Full Production
The manufacturer initiated a trial phase to evaluate the Blazer 2S Flex system, focusing on blade regions with complex geometries—root, shroud, platforms, and fillet radii.
Blade Inspection Coverage with Blazer 2S Flex
Root – Critical foundation inspection- Shroud – Ensures top-end accuracy
- Platforms – Full coverage on complex surfaces
- Fillet Radii – Precision at tight intersections
- Breaking Edges – Detects fine irregularities
- Full Profile Scan – Complete geometry capture
- IBR Slots/Holes – Detailed measurements of intricate areas
- Partial Profiles – Focused analysis for specific sections
Trial Results:
- Correlation Accuracy – Passed comparison with the customer’s GOM system, verifying precision.
- Reduced Cycle Times – Inspections were reduced from 30-35 minutes to 10-12 minutes per blade.
- Extensive Coverage – 160 dimensions were inspected per blade during each cycle.
The Impact: Driving Efficiency and Accuracy
Integrating Blazer 2S Flex into the production process resulted in significant improvements:
- Inspection Cycle Time Reduced by 65% – From 30-35 minutes to 10-12 minutes.
- 160 Dimensions Inspected – Comprehensive scanning covered all blade features, from root to fillet radii.
- Cost Savings – Automated inspection reduced labor costs and minimized rework.
- Enhanced Accuracy – Sub-micron non-contact scanning ensured compliance with stringent aerospace standards.
- Consistency and Objectivity – Fully automated processes eliminated human error.
- Scalability – Additional systems were retrofitted to increase production capacity.
Expanding Horizons: Future Scalability and Adoption
Following the successful trial, the manufacturer expanded Blazer 2S Flex deployment across multiple production lines to boost capacity and standardize inspection processes.
Future Prospects:
- Wider Retrofits – Upgrading older Blazer 2S units.
- Robotic Load/Unload Integration – Automating part handling to improve efficiency further.
- IBR Inspections – The system is also applied to IBR parts, allowing complete slot, hole, and profile analysis.
Conclusion: The Future of Blade Inspection
The transition from conventional methods to Blazer 2S Flex marks a transformative shift in quality assurance for turbine blade manufacturers. With reduced cycle times, enhanced accuracy, and automated inspection workflows, MTL 3D’s solution sets a new standard for aero engine blade inspection.
Discover how MTL 3D can enhance your inspection process at www.mtl-3d.com.
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