Preliminary optimization of an hollow Low Pressure Turbine blade

The need for higher and higher performances of automotive and aerospace structures, and the parallel request for their lightening, are the reason why the conventional productive processes, characterized by a considerable amount of castable materials, are being progressively abandoned in favour of innovative technologies, which are usually referred to as rapid prototyping. This new way of designing and realizing components has its fundamentals on the massive use of 3D printing machines, which allow to build-up, by depositing material, geometries more complex than ever before starting from a model previously generated by Computer-Aided Design (CAD) tools. Emerged in 1980s as a revolutionary technology based on a laser-induced photo-polymerization process, rapid prototyping has progressively evolved into a sophisticated process known as Additive Manufacturing, which allows to produce free-form metal objects with intricate lattice and honeycomb features, from which the final product can be eventually derived. The applications of AM range from engineering to medical industry but, although the significant advantages coming from reduced material waste, time and costs associated with materials, in addition to the mentioned capability to manufacture parts with complex internal structures, there are considerable complications due to the limited knowledge and availability of materials, 3D printing machines performance and the stages that characterize the AM process, which includes also careful cleaning of the parts and post-processing such as sanding and surface preparation. The aim of this work is to study and redesign an aeronautical engine blade taking into account the opportunities offered by Additive Manufacturing process and, subsequently, using innovative optimization methods, whose mathematical models allow to reduce systems which include a large number of degrees of freedom without losing important information of their behaviour. The thesis has been developed in collaboration with Avio Aero, "a GE Aviation business that designs, manufactures and mantains components and systems for civil and military aviation''. It is based in Rivalta di Torino and, thanks to research, development activities and partnerships with leading companies and universities, it has acquired a broad portfolio of knowledge on Additive Manufacturing processes.