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The programme traces the development of the so called nickel "superalloys" for use in jet turbine blades and how blade manufacturing processes changed to take account of the new material ...characteristics.
Metadata describing this Open University video programme
Module code and title: T351, Materials under stress
Item code: T351; 13
First transmission date: 11-09-1976
Published: 1976
Rights Statement:
Restrictions on use:
Duration: 00:23:57
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Producer: David Nelson
Contributor: Ron Jones
Publisher: BBC Open University
Keyword(s): Alloys; Engine development; Extrusion; Forging; Materials story; Milestones; Precision casting; Rolls-Royce; Turbine balde
Footage description: Ron Jones introduces the programme. He describes the specifications of a "superalloy" for a jet engine which Frank Whittle presented to the Mond Nickel Company in 1939. Jones with a model alloy cast billet. He shows the billet in cross section and points out the various grain features. Jones explains how the cast structure can be broken down by a hot extrusion process. Micrograph of a cross section after extrusion Jones explains the forging and machining operation which turns a piece of bar stock alloy into a turbine blade. He shows examples of the product at various stages in the process. Jones uses graphics on the floor of the studio to demonstrate the working temperature range of solid solution hardened nickel alloys and then precipitation hardened alloys. He points out the effect of addition of aluminium and titanium (gamma prime) on the working temperature range of nickel alloys. Micrographs show gamma prime in nickel alloy in various quantities. Jones goes on to explain the problems which can be caused by this narrowing of the temperature range. Jones explains the extrusion process for forming turbine blades and points out its advantages. He shows samples of alloys at various stages of becoming turbine blades. Film shot of the manufacturing process. Jones uses animations to explain how the gamma prime particles hinder dislocation movements in alloys. Jones uses two micrographs of nickel alloy to explain that the high concentration of gamma prime so narrows the working temperature of an alloy that a new process (precision casting) must be used to work it. Film shots of the precision casting process from mould making to the finished product at Rolls Royce Derby (1971) Ltd. Commentary by Jones. Jones looks at a micrograph showing grain structure of a turbine blade made by the precision casting process. He explains the part played by the nucleating agent in alloy crystal growth. Film shots, at Rolls Royce Derby (1971) Ltd., of heat treatment of the final product in order to precipitate out gamma prime and carbides. Commentary by Jones. Jones goes on to explain why heat treatment varies according to the application of the final product. He explains, with the aid of micrographs, the two and three stage treatments. Jones sums up and previews the next programme.
Master spool number: 6HT/72063
Production number: 00525_5264
Videofinder number: 1424
Available to public: no