Additive Manufacturing is emerging as a cost-effective alternative to conventional manufacturing techniques for applications requiring: components with complex geometries, assemblies comprising a large number of parts or small productions runs. Cost savings can be realized through reduction in raw material required, reduced manufacture times and removing the need for expensive tooling. AM can offer both an economical alternative to the existing aluminum alloy vanes. The current designs of available vanes are limited to flat/angled or hemispherical profiles. Much more sophisticated vane profiles are possible by using 3D CAD designs that can be tested by means of manufacturing vanes through AM techniques. The paper will analyze experimental and CFD simulation results of identical vanes made from AM materials to existing aluminum alloy vanes. New vane designs will also be tested, which will allow for comparisons to theoretical models for simple geometries as well as experimentation to produce more complex designs to reduce weight and increase the performance. In addition, other significant factors will also be reviewed, such as cost, build-time, finish and fitness for purpose related to AM manufactured vanes.
Rehman et al. (Mon,) studied this question.