Processing techniques for the fabrication nozzle struts: enhancing, efficiency of the micro turbine

Enhancing the airflow through micro-gas turbine engines is essential to extending their lifespan and improving their performance. This study examines how altering the nozzle strut’s design – a component that directs airflow – can aid in boosting thrust and lowering air resistance. A novel nozzle strut design was developed using numerical simulations and demonstrated a 3.5% increase in thrust over the standard design. Although standard sheet metal welding was used to create the initial prototype, the wind tunnel results differed from the computer forecasts. This occurred as a result of minor assembly-related shape problems. To address this issue, a precision milling procedure was used to create the nozzle and strut as a single unit. This strategy significantly reduced shape errors and increased surface quality, bringing the test results closer to the simulation results. The study emphasizes the need of precision production, particularly for complex-shaped parts. Even little errors can have a significant impact on performance in small engines. The effective combination of careful design and accurate manufacture demonstrates how sophisticated machining methods can help turn digital concepts into genuine, high-performance components. This method can also be utilized to produce more efficient engine components for future aerospace and energy technologies.