The engine parts that 'fight the laws of the universe'
Summary
Jet engines use turbine blades made from a single crystal of metal alloy to withstand intense heat and mechanical stress. Manufacturers create each blade by carefully cooling molten alloy and using a small spiral feature, called a pigtail, to guide the formation of one crystal rather than many grains.Key Facts
- Turbine blades can face temperatures above 1,500C and substantial mechanical stress.
- The single-crystal casting method was developed in the 1960s.
- During casting, manufacturers cool molten alloy gradually so one crystal forms in the blade.
- A pigtail spiral helps select one growing crystal; workers cut it off after casting.
- Only a small number of companies and countries have mastered the process.
- Rolls-Royce, GE and France’s Safran are among the companies that make single-crystal turbine blades.
- GE Aerospace announced in September that it would buy its turbine-blade supplier for $11.75 billion.
- Rolls-Royce said in March it would invest more than £19 million in its blade-casting facility in Rotherham.
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