Testing of components and systems is a specialized discipline that often involves complex instrumentation schemes, dedicated test rigs, and meticulous interpretation of results after assessing measurement accuracies. Turbine blades, especially those made of super alloys like Nimonic, have been subjected to vibration testing for over seven decades for research, design validation, and quality control. In recent years, advancements in 3D printing have transformed manufacturing processes, evolving from plastic powders and filaments to metal powders, enabling the production of functional components for industrial applications. Small turbine blades have been successfully manufactured using additive manufacturing (AM) techniques, particularly for wind tunnel and vibration testing, to support design and performance evaluation. This paper presents the experimental investigations conducted on a 3D-printed gas turbine stage blade subjected to vibration testing. The study outlines the test methodologies, instrumentation, and data acquisition techniques employed to evaluate the dynamic behavior of the printed blade. Additionally, key precautions necessary to ensure reliable testing and accurate result interpretation are discussed. A significant aspect of this work is the correlation between vibration characteristics of 3D-printed blades and actual steel blades used in gas turbines. The paper explores predictive techniques that facilitate the estimation of dynamic parameters in real turbine blades based on results obtained from 3D-printed prototypes. The findings contribute to the growing understanding of how additive manufacturing can aid in early-stage design validation and provide insights into the feasibility of using 3D-printed components for experimental testing in turbomachinery applications.
This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
3D printed arts are becoming common place in the past 5 to 7 years in view of growing confidence among the industry partners for this technology
[1]
Silwal R, Kafle A, Shrestha PS, Dahlhaug OG, Thapa B. Vibration Analysis of 3D printed runner with CNN for using deep learning in hydropower for condition monitoring. InIOP Conference Series: Earth and Environmental Science 2022 Jun 1 (Vol. 1037, No. 1, p. 012054). IOP Publishing.
. However, for applications involving dynamic loading, more studies need to be undertaken prior to these parts being accepted on a large scale
[3]
Walker G, Turner M, Hoke J, Holley AT. Experimental Test Rig for 3D Printed, Axial Compressor Utilizing a COTS Turbocharger. InAIAA Scitech 2020 Forum 2020 (p. 0866).
. Towards improving the confidence level of using 3D printed parts, various tests are undertaken in industry for checking their quality and reliability of performance
. For more than 70 years, testing systems and parts especially turbine blades composed of super alloys like Nimonic have been a crucial part of research, design, and quality assurance
[6]
Nirish M, Rajendra R. Suitability of metal additive manufacturing processes for part topology optimization–A comparative study. Materials Today: Proceedings. 2020 Jan 1; 27: 1601-7.
. Since 3D printing has advanced over the last five to eight years, components have been manufactured using plastic powders and filaments, and more recently, metal powders
[8]
Monzamodeth RS, Nicolás Iván RR, Oscar X, Bernardo HM, Osvaldo F, Fermín C, Bernardo C. Development of a wind turbine using 3D printing: A prospection of electric power generation from daily commute by car. Wind Engineering. 2022 Apr; 46(2): 376-91.
. This has made it possible to fabricate turbine blades for experimental uses including vibration and wind tunnel testing
[9]
Oh SY, Joung C, Lee S, Shim YB, Lee D, Cho GE, Jang J, Lee IY, Park YB. Condition-based maintenance of wind turbine structures: A state-of-the-art review. Renewable and Sustainable Energy Reviews. 2024 Oct 1; 204: 114799.
. The vibration properties of turbine blades made conventionally have been the subject of numerous studies
[10]
Nirish M, Rajendra R. Modeling and optimization of process parameter for fatigue strength improvement by selective laser melting of AlSi. Computational Intelligence based Optimization of Manufacturing Process for Sustainable Materials. 2023 Sep 25: 147.
. However, little is known about the vibration behavior of 3D-printed blades, especially when comparing them to real steel blades
[11]
Ligon SC, Liska R, Stampfl J, Gurr M, Mülhaupt R. Polymers for 3D printing and customized additive manufacturing. Chemical reviews. 2017 Aug 9; 117(15): 10212-90.
. Using data from 3D-printed plastic or filament-based prototypes to precisely forecast the dynamic response of actual metal turbine blades is the main problem
[12]
Wang Y, Ahmed A, Azam A, Bing D, Shan Z, Zhang Z, Tariq MK, Sultana J, Mushtaq RT, Mehboob A, Xiaohu C. Applications of additive manufacturing (AM) in sustainable energy generation and battle against COVID-19 pandemic: The knowledge evolution of 3D printing. Journal of manufacturing systems. 2021 Jul 1; 60: 709-33.
. By giving experimental results on the vibration testing of a 3D-printed gas turbine blade and going over the precautions and procedures needed to extrapolate these findings to real steel blades, this paper fills this knowledge gap
[13]
Blakey-Milner B, Gradl P, Snedden G, Brooks M, Pitot J, Lopez E, Leary M, Berto F, Du Plessis A. Metal additive manufacturing in aerospace: A review. Materials & Design. 2021 Nov 1; 209: 110008.
. In this paper, vibration tests are detailed with special reference to turbine blades. Except wind turbines and hydro turbines, turbines using steam and gas operate under very high temperatures of 600°C to 1400°C which precludes use of instrumentation on these turbine rotors to carry out measurements. The only way to overcome these limitations is to carry out model tests and projet the results using relationships obtained from Buckingham Pi theorem
[14]
Nirish M, Rajendra R. Selective laser melting process parameter simulation and topology optimization by aerospace component of AlSi10Mg alloy. InAIP Conference Proceedings 2022 Nov 29 (Vol. 2648, No. 1). AIP Publishing.
The blade which is used in the finite element analyses is manufactured by 3D printing technology in the laboratory as per the same geometry meaning that it is built 1: 1 scale for purposes of scaling studies and to validate the results of finite element analysis (FEA). The geometry of the blade and other details are shown in Figure 1, Figure 2 and the 3D process parameters are given in Table 1
[15]
Gastaldi C, Fantetti A, Berruti TM. Forced response prediction of turbine blades with flexible dampers: The impact of engineering modelling choices. Applied Sciences. 2017 Dec 27; 8(1): 34.
Figure 1. The dimensions of the blade and 3D Printer (Rapid Prototyping Machine, Formiga 100) used for manufacturing the blade (Make: EOS GMBH/Germany).
Table 1. Process parameters for conducting Vibration test used on 3-D printed blade.
Figure 2. Photo of turbine blade manufactured using 3D printing.
Precautions to be taken in the planning stages are certain precautions to be taken before carrying out the tests. Since 3D printing can be undertaken using various build schemes, it is essential to manufacture another rectangular bar with rectangular cross section termed as calibration beam to obtain properties like Young’s modulus and density which are essential parameters in vibration
[16]
Martin HR. Development of a scale model wind turbine for testing of offshore floating wind turbine systems.
. Care is taken to provide equivalent material portion in this bar corresponding to the base portion of the turbine blade. Text book values are to be avoided in the computations. Prior to the test, it is to be ensured that the vibration sensor (for example accelerometer) weighs less than one-tenth of the weight of the component
[17]
Ciang CC, Lee JR, Bang HJ. Structural health monitoring for a wind turbine system: a review of damage detection methods. Measurement science and technology. 2008 Oct 13; 19(12): 122001.
. This is because, in case of parts made with plastic powders or filaments, the density is low and consequently the weight of the part is low thereby making the above condition difficult to conform to. Clamping of the part must conform to the case actually used in actual usage of steel blades
[18]
Zhang S, He Y, Gu Y, He Y, Wang H, Wang H, Yang R, Chady T, Zhou B. UAV based defect detection and fault diagnosis for static and rotating wind turbine blade: a review. Nondestructive Testing and Evaluation. 2024 Aug 28: 1-39.
. Since material damping, which is negligible in steel, is not researched adequately, error due to this is difficult to compensate.
3. Results and Discussion
Frequency response function (FRF) measurement is carried on a model of Turbine Blade and Rectangular Beam to find out the Natural Frequencies, the FRF is a characteristic of a system that has a measured response resulting from a known applied input. The equipment used in the present Vibration testing are Instrumented Impact Hammer (Make: PCB Piezotronics), Miniature ICP accelerometer (Make: PCB Piezotronics Model 352C22) also known as “tear-drop” type and Multi-channel Data Acquisition System (Make: Miniature ICP accelerometer, Model SCM01) By making use of Miniature accelerometer shown in Figure 3(a)
[19]
Nirish M, Rajendra R, Karolla B. Laser Powder Bed Fusion Process Optimization of AlSi10Mg Alloy Using Selective Laser Melting: Dynamic Performance of Fatigue Behaviour, Microstructure, Hardness and Density. Journal of Mechanical Engineering (1823-5514). 2023 Jan 15; 20(1).
Chaturvedi I, Jandyal A, Wazir I, Raina A, Haq MI. Biomimetics and 3D printing-Opportunities for design applications. Sensors International. 2022 Jan 1; 3: 100191.
and the instrumented hammer shown in Figure 3(b), time response and frequency response are obtained, the latter being shown in Figure 4. The data from the measured location were recorded over a frequency bandwidth of 3.2 kHz. Additional data of testing are shown in Figure 5.
Figure 3. Tear drop type of accelerometer (make: PCB Piezotronics, Model 352C22), Instrumented impact hammer and the instrumentation set up comprising of (a) and (b) together with Multi-channel Data Acquisition System.
A rectangular beam is also manufactured herein termed as calibration beam (as mentioned in precautions) to evaluate Young’s modulus E value it using a bending test as shown in Figure 6
[21]
Magar SS, Sugandhi AS, Pawar SH, Khadake SB, Mallad HM. Harnessing Wind Vibration, a Novel Approach towards Electric Energy Generation-Review. IJARSCT. 2024 Oct; 4(2): 73-82.
. Loads p are varied and deflections δ are measured on the bar using a dial gauge and using the formula E= pl3 / (3 δ I). It may be emphasized that this test is necessary since E value in a 3D printing structure depends very much on the build scheme adopted and in the present case, build scheme is identical for the blade and calibration bar.
For the blade, the frequencies response functions shown in Table 2 for the blade obtained from the test are f1= 152 and f2 = 872.
Table 2. Gives the results of the vibration test.
Results for natural frequencies of the 3D printed turbine blade Natural frequencies of the 3D printed turbine blade Length (L) = 0.117m and Profile area (A) = 4.3794E-4m2
Mode No
Frequency (Hz)
1
152
2
872
The correctness of the results can be checked approximately by using the fact for a cantilever that f2/f1 = 22/3.52= 6.25 which in the case of a blade (not exactly a rectangular parallel piped) with aerofoil cross section is f2/f1 = 872/ 152=5.737 which is nearby but for the fact that the blade has stiffening effect. It is observed that higher frequencies could not be obtained due to stiffness of clamping of the blade is very high as observed in the time signal. Due to stiffening due to aerofoil shape measurement of frequencies higher than the two values is not possible as seen in time response (and not frequency response seen in the FRF
[22]
Ghalandari M, Ziamolki A, Mosavi A, Shamshirband S, Chau KW, Bornassi S. Aeromechanical optimization of first row compressor test stand blades using a hybrid machine learning model of genetic algorithm, artificial neural networks and design of experiments. Engineering Applications of Computational Fluid Mechanics. 2019 Jan 1; 13(1): 892-904.
. Use of scale factors to predict frequencies in steel blade Scale factors enable use of the results of tests on models made of any material to predict the parameters in an actual original prototype of blade. These scale factors can be obtained by making use of the well-known Buckingham Pi theorem. In those cases where a mathematical formula is directly available like in the present case 9 where the blade is almost can be represented as a cantilever beam in the absence of centrifugal and other loads), scale factors can easily be obtained and used
[23]
Liu P, Xu D, Li J, Chen Z, Wang S, Leng J, Zhu R, Jiao L, Liu W, Li Z. Damage mode identification of composite wind turbine blade under accelerated fatigue loads using acoustic emission and machine learning. Structural Health Monitoring. 2020 Jul; 19(4): 1092-103.
. The frequency of a cantilever beam is determined by using the relation (for 1st Mode).
Where m = ρAL mass/unit length. Now, defining the scale factors for each one of the parameters (except numerical constants like 3.52 above), we get from the basic theory of cantilever vibration, the frequency is given by
,
Where K - Constant.
After removing the constants,
Defining S as scale factor and subscript denoting the parameter, scale factors for different parameters are:
For length SL = ,
Moment of inertia, SI = ;
Mass/unit length Sm = ,
For Young’s modulus SE = .
One may for convenience denote subscript 1 as for 3D printed blade and subscript for steel blade. In the present case, length L, area of cross section of blade and 3D printed part A, are the same and therefore scale factors become equal to 1. E and density are different in original steel and 3D printed part. But m= Density x volume= Density x L x area. Area and L are same in both cases. So, Sm = .
Therefore, Scale factor for frequencies, .
Applying this formula with the values of = 0.486E9/2.0E9, Srho= =934 / 8100, one gets = 930, Therefore, in the steel blade the first mode frequency is 930 Hz.
4. Conclusion
The study demonstrates that 3D-printed turbine blades may be used for initial vibration testing, providing a quick and affordable prototype method for design validation. The experimental findings show that although 3D-printed blades made of plastic have different dynamic properties than steel blades, the behavior of real turbine components may be predicted with the use of suitable correction factors and techniques. The results highlight how crucial it is to take scale effects, boundary conditions, and material attributes into account when interpreting test results. Vibration tests on a model 3D printed blade is tested for natural frequencies in its fixed condition as obtaining in practice using sophisticated instrumentation after taking some precautions. In view of increasing popularity of 3D printing technologies more such tests can be undertaken for various kinds of machine components. The following experimental results are achieved from the natural frequencies for different lengths of blades under 4 modes; blade length is 100 mm at the natural frequency of the blade is at 1315 (mode 1), 2959 (mode 2), 4704 (mode 3) and 7225 (mode 4). The blade is 117 mm at the natural frequency of the blade is at 973 (mode 1), 2250 (mode 2), 4050 (mode 3) and 5535 (mode 4). The blade is 130 mm at the natural frequency of the blade is at 798 (mode 1), 1855 (mode 2), 3678 (mode 3) and 4633 (mode 4)
[24]
Ahmed A, Azam A, Bhutta MM, Khan FA, Aslam R, Tahir Z. Discovering the technology evolution pathways for 3D printing (3DP) using bibliometric investigation and emerging applications of 3DP during COVID-19. Cleaner Environmental Systems. 2021 Dec 1; 3: 100042.
Pignatelli F, Percoco G. An application-and market-oriented review on large format additive manufacturing, focusing on polymer pellet-based 3D printing. Progress in Additive Manufacturing. 2022 Dec; 7(6): 1363-77.
. For improved vibration analysis accuracy, future research should concentrate on improving prediction models and expanding 3D printing applications to metal-based turbine blades.
Abbreviations
AM
Additive Manufacturing
SLS
Selective Laser Sintering
FEA
Finite Element Analysis
RP
Rapid Prototyping
FRF
Frequency Response Function
Acknowledgments
The author sincerely thanks CPDDAM for SLS printing, Research Dean and Principal for encouraging advanced research conducted at UCE (A), OU. The authors also extend their gratitude to Mr. K. Rajendra Prasad, Chief Executive Officer/Managing Director (CEO/MD), and Ms. K. Lavanya, Executive Director (ED) of Measure India Corporation Pvt. Ltd. (MICPL), Hyderabad, for their invaluable assistance and cooperation in facilitating the mechanical testing.
1. 3D Printing Process: An illustration showing the transition from plastic/metal powder to a 3D-printed turbine blade.
2. Vibration Testing Setup: A schematic of a test rig where the 3D-printed turbine blade is undergoing vibration analysis.
3. Comparison with Steel Blade: A diagram indicating the correlation between test results of the 3D-printed blade and predictions for actual steel blades.
1. Specialized Testing: Discusses the complexities of component testing, including instrumentation, test rigs, and result interpretation.
2. Turbine Blade Testing: Highlights the long-established practice of vibration testing for turbine blades made of super alloys like Nimonic.
3. Advancement in 3D Printing: Explores the evolution of additive manufacturing from plastic powders and filaments to metal powders in the last 5-8 years.
4. Application of 3D-Printed Blades: Examines the use of 3D-printed turbine blades for wind tunnel and vibration tests.
5. Experimental Investigation: Presents vibration test results of a 3D-printed gas turbine blade.
6. Correlation with Steel Blades: Discusses methods to predict actual steel blade parameters from 3D-printed blade test results.
7. Precautionary Measures: Highlights necessary precautions when conducting vibration tests on 3D-printed blades.
References
[1]
Silwal R, Kafle A, Shrestha PS, Dahlhaug OG, Thapa B. Vibration Analysis of 3D printed runner with CNN for using deep learning in hydropower for condition monitoring. InIOP Conference Series: Earth and Environmental Science 2022 Jun 1 (Vol. 1037, No. 1, p. 012054). IOP Publishing.
Walker G, Turner M, Hoke J, Holley AT. Experimental Test Rig for 3D Printed, Axial Compressor Utilizing a COTS Turbocharger. InAIAA Scitech 2020 Forum 2020 (p. 0866).
Nirish M, Rajendra R. Suitability of metal additive manufacturing processes for part topology optimization–A comparative study. Materials Today: Proceedings. 2020 Jan 1; 27: 1601-7.
Monzamodeth RS, Nicolás Iván RR, Oscar X, Bernardo HM, Osvaldo F, Fermín C, Bernardo C. Development of a wind turbine using 3D printing: A prospection of electric power generation from daily commute by car. Wind Engineering. 2022 Apr; 46(2): 376-91.
Oh SY, Joung C, Lee S, Shim YB, Lee D, Cho GE, Jang J, Lee IY, Park YB. Condition-based maintenance of wind turbine structures: A state-of-the-art review. Renewable and Sustainable Energy Reviews. 2024 Oct 1; 204: 114799.
Nirish M, Rajendra R. Modeling and optimization of process parameter for fatigue strength improvement by selective laser melting of AlSi. Computational Intelligence based Optimization of Manufacturing Process for Sustainable Materials. 2023 Sep 25: 147.
Ligon SC, Liska R, Stampfl J, Gurr M, Mülhaupt R. Polymers for 3D printing and customized additive manufacturing. Chemical reviews. 2017 Aug 9; 117(15): 10212-90.
Wang Y, Ahmed A, Azam A, Bing D, Shan Z, Zhang Z, Tariq MK, Sultana J, Mushtaq RT, Mehboob A, Xiaohu C. Applications of additive manufacturing (AM) in sustainable energy generation and battle against COVID-19 pandemic: The knowledge evolution of 3D printing. Journal of manufacturing systems. 2021 Jul 1; 60: 709-33.
Blakey-Milner B, Gradl P, Snedden G, Brooks M, Pitot J, Lopez E, Leary M, Berto F, Du Plessis A. Metal additive manufacturing in aerospace: A review. Materials & Design. 2021 Nov 1; 209: 110008.
Nirish M, Rajendra R. Selective laser melting process parameter simulation and topology optimization by aerospace component of AlSi10Mg alloy. InAIP Conference Proceedings 2022 Nov 29 (Vol. 2648, No. 1). AIP Publishing.
Gastaldi C, Fantetti A, Berruti TM. Forced response prediction of turbine blades with flexible dampers: The impact of engineering modelling choices. Applied Sciences. 2017 Dec 27; 8(1): 34.
Ciang CC, Lee JR, Bang HJ. Structural health monitoring for a wind turbine system: a review of damage detection methods. Measurement science and technology. 2008 Oct 13; 19(12): 122001.
Zhang S, He Y, Gu Y, He Y, Wang H, Wang H, Yang R, Chady T, Zhou B. UAV based defect detection and fault diagnosis for static and rotating wind turbine blade: a review. Nondestructive Testing and Evaluation. 2024 Aug 28: 1-39.
Nirish M, Rajendra R, Karolla B. Laser Powder Bed Fusion Process Optimization of AlSi10Mg Alloy Using Selective Laser Melting: Dynamic Performance of Fatigue Behaviour, Microstructure, Hardness and Density. Journal of Mechanical Engineering (1823-5514). 2023 Jan 15; 20(1).
Chaturvedi I, Jandyal A, Wazir I, Raina A, Haq MI. Biomimetics and 3D printing-Opportunities for design applications. Sensors International. 2022 Jan 1; 3: 100191.
Magar SS, Sugandhi AS, Pawar SH, Khadake SB, Mallad HM. Harnessing Wind Vibration, a Novel Approach towards Electric Energy Generation-Review. IJARSCT. 2024 Oct; 4(2): 73-82.
Ghalandari M, Ziamolki A, Mosavi A, Shamshirband S, Chau KW, Bornassi S. Aeromechanical optimization of first row compressor test stand blades using a hybrid machine learning model of genetic algorithm, artificial neural networks and design of experiments. Engineering Applications of Computational Fluid Mechanics. 2019 Jan 1; 13(1): 892-904.
Liu P, Xu D, Li J, Chen Z, Wang S, Leng J, Zhu R, Jiao L, Liu W, Li Z. Damage mode identification of composite wind turbine blade under accelerated fatigue loads using acoustic emission and machine learning. Structural Health Monitoring. 2020 Jul; 19(4): 1092-103.
Ahmed A, Azam A, Bhutta MM, Khan FA, Aslam R, Tahir Z. Discovering the technology evolution pathways for 3D printing (3DP) using bibliometric investigation and emerging applications of 3DP during COVID-19. Cleaner Environmental Systems. 2021 Dec 1; 3: 100042.
Pignatelli F, Percoco G. An application-and market-oriented review on large format additive manufacturing, focusing on polymer pellet-based 3D printing. Progress in Additive Manufacturing. 2022 Dec; 7(6): 1363-77.
Karolla, B., Nirish, M., Rajendra, R. (2025). Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. American Journal of Mechanical and Materials Engineering, 9(2), 50-56. https://doi.org/10.11648/j.ajmme.20250902.12
Karolla, B.; Nirish, M.; Rajendra, R. Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. Am. J. Mech. Mater. Eng.2025, 9(2), 50-56. doi: 10.11648/j.ajmme.20250902.12
Karolla B, Nirish M, Rajendra R. Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. Am J Mech Mater Eng. 2025;9(2):50-56. doi: 10.11648/j.ajmme.20250902.12
@article{10.11648/j.ajmme.20250902.12,
author = {Buschaiah Karolla and Mudda Nirish and Rega Rajendra},
title = {Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design
},
journal = {American Journal of Mechanical and Materials Engineering},
volume = {9},
number = {2},
pages = {50-56},
doi = {10.11648/j.ajmme.20250902.12},
url = {https://doi.org/10.11648/j.ajmme.20250902.12},
eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajmme.20250902.12},
abstract = {Testing of components and systems is a specialized discipline that often involves complex instrumentation schemes, dedicated test rigs, and meticulous interpretation of results after assessing measurement accuracies. Turbine blades, especially those made of super alloys like Nimonic, have been subjected to vibration testing for over seven decades for research, design validation, and quality control. In recent years, advancements in 3D printing have transformed manufacturing processes, evolving from plastic powders and filaments to metal powders, enabling the production of functional components for industrial applications. Small turbine blades have been successfully manufactured using additive manufacturing (AM) techniques, particularly for wind tunnel and vibration testing, to support design and performance evaluation. This paper presents the experimental investigations conducted on a 3D-printed gas turbine stage blade subjected to vibration testing. The study outlines the test methodologies, instrumentation, and data acquisition techniques employed to evaluate the dynamic behavior of the printed blade. Additionally, key precautions necessary to ensure reliable testing and accurate result interpretation are discussed. A significant aspect of this work is the correlation between vibration characteristics of 3D-printed blades and actual steel blades used in gas turbines. The paper explores predictive techniques that facilitate the estimation of dynamic parameters in real turbine blades based on results obtained from 3D-printed prototypes. The findings contribute to the growing understanding of how additive manufacturing can aid in early-stage design validation and provide insights into the feasibility of using 3D-printed components for experimental testing in turbomachinery applications.
},
year = {2025}
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TY - JOUR
T1 - Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design
AU - Buschaiah Karolla
AU - Mudda Nirish
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Y1 - 2025/03/31
PY - 2025
N1 - https://doi.org/10.11648/j.ajmme.20250902.12
DO - 10.11648/j.ajmme.20250902.12
T2 - American Journal of Mechanical and Materials Engineering
JF - American Journal of Mechanical and Materials Engineering
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AB - Testing of components and systems is a specialized discipline that often involves complex instrumentation schemes, dedicated test rigs, and meticulous interpretation of results after assessing measurement accuracies. Turbine blades, especially those made of super alloys like Nimonic, have been subjected to vibration testing for over seven decades for research, design validation, and quality control. In recent years, advancements in 3D printing have transformed manufacturing processes, evolving from plastic powders and filaments to metal powders, enabling the production of functional components for industrial applications. Small turbine blades have been successfully manufactured using additive manufacturing (AM) techniques, particularly for wind tunnel and vibration testing, to support design and performance evaluation. This paper presents the experimental investigations conducted on a 3D-printed gas turbine stage blade subjected to vibration testing. The study outlines the test methodologies, instrumentation, and data acquisition techniques employed to evaluate the dynamic behavior of the printed blade. Additionally, key precautions necessary to ensure reliable testing and accurate result interpretation are discussed. A significant aspect of this work is the correlation between vibration characteristics of 3D-printed blades and actual steel blades used in gas turbines. The paper explores predictive techniques that facilitate the estimation of dynamic parameters in real turbine blades based on results obtained from 3D-printed prototypes. The findings contribute to the growing understanding of how additive manufacturing can aid in early-stage design validation and provide insights into the feasibility of using 3D-printed components for experimental testing in turbomachinery applications.
VL - 9
IS - 2
ER -
Karolla, B., Nirish, M., Rajendra, R. (2025). Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. American Journal of Mechanical and Materials Engineering, 9(2), 50-56. https://doi.org/10.11648/j.ajmme.20250902.12
Karolla, B.; Nirish, M.; Rajendra, R. Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. Am. J. Mech. Mater. Eng.2025, 9(2), 50-56. doi: 10.11648/j.ajmme.20250902.12
Karolla B, Nirish M, Rajendra R. Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design. Am J Mech Mater Eng. 2025;9(2):50-56. doi: 10.11648/j.ajmme.20250902.12
@article{10.11648/j.ajmme.20250902.12,
author = {Buschaiah Karolla and Mudda Nirish and Rega Rajendra},
title = {Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design
},
journal = {American Journal of Mechanical and Materials Engineering},
volume = {9},
number = {2},
pages = {50-56},
doi = {10.11648/j.ajmme.20250902.12},
url = {https://doi.org/10.11648/j.ajmme.20250902.12},
eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajmme.20250902.12},
abstract = {Testing of components and systems is a specialized discipline that often involves complex instrumentation schemes, dedicated test rigs, and meticulous interpretation of results after assessing measurement accuracies. Turbine blades, especially those made of super alloys like Nimonic, have been subjected to vibration testing for over seven decades for research, design validation, and quality control. In recent years, advancements in 3D printing have transformed manufacturing processes, evolving from plastic powders and filaments to metal powders, enabling the production of functional components for industrial applications. Small turbine blades have been successfully manufactured using additive manufacturing (AM) techniques, particularly for wind tunnel and vibration testing, to support design and performance evaluation. This paper presents the experimental investigations conducted on a 3D-printed gas turbine stage blade subjected to vibration testing. The study outlines the test methodologies, instrumentation, and data acquisition techniques employed to evaluate the dynamic behavior of the printed blade. Additionally, key precautions necessary to ensure reliable testing and accurate result interpretation are discussed. A significant aspect of this work is the correlation between vibration characteristics of 3D-printed blades and actual steel blades used in gas turbines. The paper explores predictive techniques that facilitate the estimation of dynamic parameters in real turbine blades based on results obtained from 3D-printed prototypes. The findings contribute to the growing understanding of how additive manufacturing can aid in early-stage design validation and provide insights into the feasibility of using 3D-printed components for experimental testing in turbomachinery applications.
},
year = {2025}
}
TY - JOUR
T1 - Vibration Testing of 3D-Printed Turbine Blades: Precautions and the Application of Scale Factors in Design
AU - Buschaiah Karolla
AU - Mudda Nirish
AU - Rega Rajendra
Y1 - 2025/03/31
PY - 2025
N1 - https://doi.org/10.11648/j.ajmme.20250902.12
DO - 10.11648/j.ajmme.20250902.12
T2 - American Journal of Mechanical and Materials Engineering
JF - American Journal of Mechanical and Materials Engineering
JO - American Journal of Mechanical and Materials Engineering
SP - 50
EP - 56
PB - Science Publishing Group
SN - 2639-9652
UR - https://doi.org/10.11648/j.ajmme.20250902.12
AB - Testing of components and systems is a specialized discipline that often involves complex instrumentation schemes, dedicated test rigs, and meticulous interpretation of results after assessing measurement accuracies. Turbine blades, especially those made of super alloys like Nimonic, have been subjected to vibration testing for over seven decades for research, design validation, and quality control. In recent years, advancements in 3D printing have transformed manufacturing processes, evolving from plastic powders and filaments to metal powders, enabling the production of functional components for industrial applications. Small turbine blades have been successfully manufactured using additive manufacturing (AM) techniques, particularly for wind tunnel and vibration testing, to support design and performance evaluation. This paper presents the experimental investigations conducted on a 3D-printed gas turbine stage blade subjected to vibration testing. The study outlines the test methodologies, instrumentation, and data acquisition techniques employed to evaluate the dynamic behavior of the printed blade. Additionally, key precautions necessary to ensure reliable testing and accurate result interpretation are discussed. A significant aspect of this work is the correlation between vibration characteristics of 3D-printed blades and actual steel blades used in gas turbines. The paper explores predictive techniques that facilitate the estimation of dynamic parameters in real turbine blades based on results obtained from 3D-printed prototypes. The findings contribute to the growing understanding of how additive manufacturing can aid in early-stage design validation and provide insights into the feasibility of using 3D-printed components for experimental testing in turbomachinery applications.
VL - 9
IS - 2
ER -
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