Abstract: For electrolytically etching the surfaces of integrally bladed rotors (blisks) (6) made of nickel-base material for aircraft gas turbines, auxiliary cathodes (10), in addition to the main cathodes (3) provided in the electrolyte (1), are arranged in the area of the blades (9) remote from the electric contact points at the rotor disk (7). The auxiliary cathodes are adaptable in shape, arrangement and size to the blade and disk geometry, so that a uniform current flow from all parts of the rotor connected as anode via the electrolyte to the main and auxiliary cathodes is produced and an intense and uniform etching effect is achieved. This ensures a reliable structural assessment in all rotor areas and in particular also in the area of the integral blading.

Abstract: With rotor wheel drums with integrally formed-on and/or separately attached blading (3, 8) blade tip machining is performed for the completely mounted drum assembly (1, 5) connected to a driven auxiliary turbomachine shaft acting as workpiece carrier (13) in a single apparatus by dry machining the separably assembled blades (8) and by wet machining the integrally formed-on blades (3), with the rotational speed of the workpiece carrier being lower in the wet machining process than in the dry machining process. The area for dry machining is protected by a shield (19) adjustable in the respective separating position against the matter generated in wet machining. Notwithstanding the fact that drums with integrally formed-on blades can be machined without being damaged, optimum gap conditions and correspondingly higher efficiency can be obtained.

Abstract: A method for manufacturing a blisk for a gas turbine, in particular an aircraft gas turbine, includes generating blade profiles from an outer contour of a forged disk by milling and/or electrochemical machining. A robot-controlled, mechanical rework is performed of blade areas, in areas of the leading and trailing edges, the annulus, the fillet, the platform and the blade tip. A specified contour according to the engineering drawing of the blisk blade areas is referenced and an actual contour is determined by visualization. A difference between the specified contour and the actual contour is then calculated. The blade areas are then finish-machined and polished in a special processing machine according to a program prepared on the basis of the calculated difference.

Abstract: For electrolytically etching the surfaces of integrally bladed rotors (blisks) (6) made of nickel-base material for aircraft gas turbines, auxiliary cathodes (10), in addition to the main cathodes (3) provided in the electrolyte (1), are arranged in the area of the blades (9) remote from the electric contact points at the rotor disk (7). The auxiliary cathodes are adaptable in shape, arrangement and size to the blade and disk geometry, so that a uniform current flow from all parts of the rotor connected as anode via the electrolyte to the main and auxiliary cathodes is produced and an intense and uniform etching effect is achieved. This ensures a reliable structural assessment in all rotor areas and in particular also in the area of the integral blading.

Abstract: When manufacturing welded blisk drums for gas-turbine engines, two or more integrally bladed blisks are joined to a blisk drum by welding, with this drum being subsequently heat-treated. In the final processing step, the blisk blades are polished, with the blisk drum as a whole being immerged into a flowable, pasty abrasive medium, and with a relative movement between the blisk drum and the abrasive medium being generated by translation and/or vibration and/or rotation of the blisk drum or a tub containing the abrasive medium. In order to avoid changes in shape of the blade edges during polishing, relative movement in these areas is prevented by guiding elements. The blade edges may also be masked, or surplus material may be provided on the blade edges, which afterwards is removed during grinding.

Abstract: With rotor wheel drums with integrally formed-on and/or separately attached blading (3, 8) blade tip machining is performed for the completely mounted drum assembly (1, 5) connected to a driven auxiliary turbomachine shaft acting as workpiece carrier (13) in a single apparatus by dry machining the separably assembled blades (8) and by wet machining the integrally formed-on blades (3), with the rotational speed of the workpiece carrier being lower in the wet machining process than in the dry machining process. The area for dry machining is protected by a shield (19) adjustable in the respective separating position against the matter generated in wet machining. Notwithstanding the fact that drums with integrally formed-on blades can be machined without being damaged, optimum gap conditions and correspondingly higher efficiency can be obtained.