Investment Casting

In 1996 Elmec ventured into a research project to create the hot section parts for non-current models of Industrial Gas Turbine engines. These superalloy parts are normally cast in a Vacuum Induction Melter (VIM). The Investment casting process is also known as the “Lost wax” method. Through a grant to the University of British Columbia, we enlisted the support from the Department of Metals and Materials Engineering for assistance. Our program was headed by Dr Alec Mitchell, Professor of Metallurgy, and Director of The Advanced Materials and Processes Engineering Laboratories ( AMPEL ), one of the world’s leading authorities in the field.

Through a unique “In-Situ” process which Elmec developed over this three year program, we have successfully cast parts Directionally Solidified (DS) and Single Crystal (SC) in crystalline structure at costs significantly below the industry standard. It is now possible to replace Stage 1 Turbine blades in older gas turbines, with new superior models DS cast in the latest superalloys, a metallurgical structure usually reserved for aircraft engines, due to its high cost. The Industrial sector usually cannot afford the higher cost of the latest technological developments and as such, the benefits of the increased performance and efficiencies and not extended to that it, unless they acquire the latest models of turbine engines. Most manufacturers will not retrofit their older turbines with advanced technologies. Since many of the turbines in use in the pipeline or electrical generation industry, are of non-current design and some are no longer being supported by the manufacturers, finding OEM parts is becoming increasingly difficult, let alone those retrofitted in the latest alloys. It is therefore incumbent on the aftermarket suppliers like Elmec to meet this demand.

Parts that we manufacture by casting include:

Turbine Blades
Nozzle Guide Vanes
Fuel Nozzles
Combustor Inlet snouts
IGV Actuators

We have concluded the research on the DS metallurgy on the aftermarket LM1500 blades and have test run the blades in a rainbow of two alloys. The next phase will be performance and endurance trials. We are now ready to produce these blades for clients.

When the complete set of blades for the Avon 1533 is finished early 2001, it too will be test fired. These engines will be run in the test cell facilities at one of our clients, S & S Turbine Services, in Fort St. John, B.C.