Performance of Die Coatings Used in Injection Moulding of Ceramic Components

EPSRC supported EngD project: Performance of Die Coatings Used in Injection Moulding of Ceramic Components

Rolls Royce (Derby)
Prof S Blackburn (University of Birmingham)

Rolls-Royce is one of the world’s leading industrial technology companies. Within the Civil Aerospace division sits the Turbines supply chain unit. Turbines are the source of competitive advantage for Rolls-Royce through the design of the Turbine sub-system, and through the design, manufacture and supply of turbine modules and gas-path components. We have a dedicated ceramic core and casting research facility based in Ansty called the High Temperature Research Centre (HTRC) a partnership with the University of Birmingham.
This exciting tribology project with Rolls Royce plc will explore the factors leading to the premature failure of PVD coatings. The coatings are applied to injection moulding dies used to form vital sacrificial components,which are used in the manufacture of aerospace jet engines. The components used in the turbine stages of the engine are cast from nickel based superalloy around a silica based ceramic core. The “core” is then chemically-leached from the blade to leave cooling channels within the turbine blade which allow it to withstand the high temperatures experienced during the operation of the engine. Environmental and performance targets drive a continued evolution of the turbine blade designs requiring more complex ceramic cores.