Pratt & Whitney has successfully tested a 3D-printed turbine wheel for the TJ150 small turbojet engine for the first time. The test marks a step forward in the additive manufacturing of rotating engine components, which were previously considered particularly challenging. While static components such as housings or air guide elements have already been additively manufactured for years, rotating parts place higher demands on material integrity, tolerances and operational stability.
The TJ150 is a lightweight turbojet engine with 150 pounds of thrust that was developed for unmanned systems and short-lived applications. For single-use platforms in particular, the focus is on a favorable performance-to-manufacturing cost ratio.
“Today we’re fielding and flying static engine parts. Rotating engine components, especially for expendable class applications, is the next step,” said Chris Hugill, executive director of Pratt & Whitney GATORWORKS. “Our testing confirms we’re on track with the engine performing at full operating speeds and temperatures and meeting expected life duration. This technology is transforming how we design, develop and deliver capabilities faster.”
The project is based on close cooperation between the development teams at GATORWORKS and the RTX Technology Research Center. A central element was the use of the so-called unitization process, in which the number of individual components within the core module was greatly reduced through function-integrated design. Instead of over 50 conventional parts, the module now consists of just a few additively manufactured components. This not only reduces production time, but also reduces potential sources of error in the assembly process.
With a development time of just eight months for design, production and testing, the project demonstrates the possibilities of additive processes in the fast-moving environment of defense technology applications. The successful validation of the turbine wheel paves the way for further 3D-printed high-speed components in jet engines.
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