Assessing manufacturing threats in aero engine components: disc and blades

Aero engine components, particularly BLISKs, are among the most expensive and challenging to manufacture due to their intricate geometry. BLISKs integrate the disc and blades into a single unit, introducing various threats that impact product quality, operational time, and production costs. An extensive literature review identified key threats, including component geometry/design, manufacturing process complexity, and advanced material processing. While the industry has developed solutions to enhance BLISK manufacturing, a comprehensive assessment of threats across the entire process chain is lacking. This research evaluates major threats in the BLISK manufacturing process, identifying four primary threat dimensions, seven primary variables, and 18 secondary variables. A fuzzy logic-based threat assessment model was developed to optimise variable values and minimise manufacturing threats. The model's findings were validated against previous experimental results, providing a robust framework to address challenges in BLISK manufacturing.