1. Material Selection and Melting
High-Temperature Alloys: Nickel-based/cobalt-based alloys (such as Inconel 718) are the mainstream, requiring the addition of elements such as Al and Ti to form γ' strengthening phases.
Directional Solidification/Single Crystal Technology: Columnar or single-crystal structures are obtained by controlling the cooling rate, eliminating transverse grain boundaries and improving high-temperature creep resistance.
Purity Control: A dual process of vacuum induction melting (VIM) + electroslag remelting (ESR) is used to control impurity content at the ppm level.
2. Precision Casting
Ceramic Shell Process:
Wax Injection Molding: Tolerances controlled within ±0.1mm
Multi-Layer Ceramic Coating: Silica sol bonding of alumina/zirconia, followed by high-temperature sintering to form a hollow shell.
Pouring Parameters: Ultra-high temperature casting above 1600℃, combined with electromagnetic field suppression of turbulence to reduce porosity defects.
3. Machining
Five-Axis Milling:
Uses diamond-coated tools, spindle speed above 30,000 rpm
Blade profile error < 0.05mm, surface roughness Ra 0.4μm
Electrochemical Machining (ECM):
For difficult-to-machine materials, formed through anodic dissolution, without mechanical stress
Accuracy up to ±0.03mm, suitable for complex internal cooling channels
4. Cooling Structure Manufacturing
Film Hole Machining:
Laser Drilling (nanosecond/picosecond laser): Hole diameter 0.3-1.2mm, tilt angle 20°-90°
Electrical Discharge Machining (EDM): Used for machining irregularly shaped holes, avoiding recast layers
Internal Cavity Structure:
3D Printing (SLM): Directly forms conformal cooling channels
Diffusion Welding: Multi-layer ultra-thin plate stacking welding, channel height 0.5-2mm
5. Surface Strengthening Technologies
Thermal Barrier Coatings (TBCs):
Dual-layer structure: MCrAlY binder layer (100-150μm) + Yttrium-stabilized zirconia (YSZ, 200-300μm)
Action plasma spraying (APS) or electron beam physical vapor deposition (EB-PVD)
Laser shock peening (LSP):
Power density at the GW/cm² level, inducing residual compressive stress depth up to 1-2mm
Fatigue life increased by 3-5 times