Advancing High-Pressure Turbine Vane Cooling Efficiency Through Additive Manufacturing: Insights From the 3DCeraTurb Project

Abstract The efficiency of modern gas turbines and jet engines is closely tied to the permissible operating temperatures of the materials used. As the inlet temperature of high-pressure turbines rises, the need for advanced cooling techniques becomes critical, demanding the development of robust materials and innovative fabrication methods. Research at the German Aerospace center (DLR) aims at furthering and exploiting additive manufacturing technologies to addresses these challenges by developing turbine vanes with intricate cooling structures suited particularly for fabrication with Laser Powder Bed Fusion. In the highly interdisciplinary 3DCeraTurb project, a new double wall vane design with advanced cooling concepts is being developed, materials studied as well as demonstrators realized and tested. The aim is to achieve a more efficient cooling to enhance engine performance and enable fuel savings and emission reductions. This contribution aims to provide a general overview on the investigations in 3DCeraTurb with a focus on the additive manufacturing process developments and materials studies. Beyond the production of advanced turbine vanes, the project has enabled advancements across the production chain, including heat treatment, mechanical property optimization, and post-processing of surfaces. 3DCeraTurb marks a significant step toward in exploiting additive manufacturing for enhancing turbine efficiency and reliability in extreme operating environments.