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Electroforming micro gas turbine components

Dear people, We are hoping to manufacture micro gas turbine components, could you suggest a suitable process for small scale production. Temperatures in the range of 500-900 °C are more than likely. Many thanks in advance, Chris

Chris Darzy
small electroform company - Utah
July 28, 2008

Not knowing the limits of the temperature affect on the parts, my first thought would be no. What type of tolerance does it have to maintain and how much degradation of the original strength can you stand. 900 °C is really really hot for most as plated metals. That is why the turbine blades are made of exotic alloys and why they have cooling laminar flow air vented thru the first 2 stages of newer engines. Go into your engineering books to find what might work and then look up what the limits of plated metal are. Electroplated nickel is much lower in the melting point than pure nickel is.

James Watts
- Navarre, Florida
July 31, 2008

I agree with Jim, but don't forget that temperature gradients and a proper design may provide some cooling to keep the un-exposed bulk metal at a safer temperature than the superficial layer. Molds for the continuous casting of steel strip are coated with thick nickel inside to protect the copper bulk metal. This nickel is constantly seeing temperatures of around 1,600oC (well above its melting point of 1450oC). There are also fire nozzles and combustion chambers made of cheaper metals and they work since they get some cooling. My advise would be to go ahead with care. Check the Nickel Institute publications.

Guillermo Marrufo
Monterrey, NL, Mexico
August 1, 2008