High fidelity replication of surface texture and geometric form of a high aspect ratio aerodynamic test component

This paper details, assesses and validates a technique for the replication of a titanium wind tunnel test
aerofoil in polyurethane resin. Existing resin replication techniques are adapted to overcome the
technical difficulties associated with casting a high aspect ratio component. The technique is shown to
have high replication fidelity over all important length-scales. The blade chord was accurate to 0.02%,
and the maximum blade thickness was accurate to 2.5%. Important spatial and amplitude areal
surface texture parameter were accurate to within 2%. Compared to an existing similar system using
correlation areal parameters the current technique is shown to have lower fidelity and this difference is
discussed. The current technique was developed for the measurement of boundary layer flow‘laminar
to turbulent’ transition for gas turbine compressor blade profiles and this application is illustrated.