A decision-making process in order to apply additive manufacturing technology in a gas-turbine’s fuel Swirler

Purpose This paper aims to assess the feasibility of using additive manufacturing (AM) to produce a gas-turbine’s fuel swirler, thereby validating its suitability for this fabrication process. This study involves a statistical comparison of the AM process with other manufacturing methods, utilizing a multi-criteria decision-making approach to determine the most favorable method for the component. This study also includes the manufacturing of the component and an evolution of the quality control results to ascertain the component’s compliance with required standards. Design/methodology/approach To compare the different fabrication methods, this paper uses the analytic hierarchy process to compare AM with alternative manufacturing processes, generating different scenarios for comparison. In addition, two samples of the component were additively manufactured to assess their suitability for application in a small gas turbine. Findings The results indicate that AM was identified as eligible and adequate process for producing the fuel swirler in most scenarios. This study includes the results of a nondestructive quality control process and provides a comprehensive discussion aiming to optimize the component’s quality. These results support the potential for scaling up the production of this component and identifying other components that may benefit from AM. Originality/value This research contributes to the advancement of technical knowledge regarding the application of an innovative manufacturing method for jet engine components. It aims to enhance manufacturing capabilities for different thermal machine parts while reducing design costs.