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Application of the Mold SDM Process to the Fabrication of Ceramic Parts for a Micro Gas Turbine Engine

A micro gas turbine engine with silicon nitride parts is being developed. In this project, the Mold Shape Deposition Manufacturing (Mold SDM) process is used to fabricate high quality ceramic parts with complex shapes such as the rotor group. The merits of micro gas turbine engines in general are described before focusing on processing and fabrication issues. The obtained silicon nitride parts are characterized concerning their mechanical and microstructural properties. The surface roughness, shrinkage during sintering, final density and achievable feature sizes have been determined. Using Mold SDM a functional rotor group has been successfully fabricated. During spin tests at room temperature with nitrogen as driving gas 456,000 rpm rotational speed has been achieved.