MecWash has collaborated with a leading UK-based aerospace manufacturer since 2010, to design, develop and build a cutting-edge component cleaning system tailored specifically for turbine blades. The initial BladeWash system has delivered consistently exceptional results, prompting the manufacturer to invest in four additional systems to support their growing workload, the most recent delivered in 2024.
Headquartered in Tewkesbury, Gloucestershire, MecWash has been creating bespoke wash systems (where our standard range does not suit the application) and chemical cleaning solutions for manufacturers worldwide for over 30 years. The company has a strong track record in the aerospace sector, developing component cleaning processes for applications ranging from engine components, complex actuation controls and sensors to fasteners.
Meeting the cleanliness specifications and providing a flawless finish on these blades is essential. The turbine blades, made from nickel-based super alloys, must be meticulously cleaned to remove casting media before they can be used in an engine assembly. Washing the internal features of turbine blades posed a unique challenge for MecWash. The internal cooling channels of the blades, accessed only through small orifices, require careful flushing to ensure proper functionality. The BladeWash is specifically designed to flush the internal cooling cores of high and medium-pressure turbine blades, cleaning out contaminants and ultimately reducing the risk of blade failure caused by impaired cooling.
The BladeWash system has delivered consistently exceptional results, prompting the manufacturer to invest in five systems
In order to address this challenge, MecWash engaged in extensive discussions and cleaning trials with the customer to fully understand the application and material requirements. With this information, the development of the BladeWash system began. After constructing a prototype and successfully completing trial runs, the first production version was installed and has been in continuous operation ever since. Since the original prototype machine the customer has purchased a further four machines.
Over the past 15 years, MecWash has supported its customer by incorporating the latest technology and optimising the BladeWash system for even greater efficiency, helping reduce downtime and ensure top performance.
Gareth Palfreyman, Head of Design at MecWash, played a key role in the development of the BladeWash system.
“The latest iteration of the BladeWash features upgraded components that reduce turbulence and enhance fluid flow efficiency within a compact machine design. These improvements decrease the energy required to pump the wash medium. We’ve also integrated high-performance process valves to extend service intervals and minimize downtime.
“The thermal efficiency of the machine has been increased, reducing energy consumption and lowering operational costs. Additionally, the BladeWash system now features full IO-Link compatibility, improving connectivity and monitoring at the factory level. This allows for real-time service tracking and usage data, which can be tailored to the customer’s specific needs. The updated system also meets Category 3 safety standards, a vital requirement for aerospace applications,” Gareth explained.
John Pattison, Managing Director of MecWash, commented:
“At MecWash, we fully understand the exacting demands of the aerospace industry. The component cleaning systems we develop not only meet but exceed compliance standards, delivering consistent results that boost productivity. The customer’s purchase of five BladeWash systems is a testament to the reliability and effectiveness of the technology. The BladeWash system is a prime example of the innovation and support MecWash provides to its clients. Its powerful washing capabilities and precision jetting are consistently effective for customers working with these intricate components.”
The BladeWash system has been updated to provide even greater efficiency, helping reduce downtime and ensure top performance.