Additive Manufacturing of Abradable Mesh on Turbine Ring Segments

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Solution Overview

Problem

Current methods for creating abradable surfaces on gas turbine components, such as turbine ring segments, are costly due to subtractive manufacturing techniques, which are inefficient for producing complex geometries and maintaining tight clearance between turbine blades and opposing components under high temperatures and thermal growth.

Innovation Solution

An abradable mesh structure is created using additive manufacturing, specifically Laser Powder Forming, where a bond coat and thermal barrier coating are applied, followed by depositing interlacing strands of varying heights to form a complex geometry abradable surface that can withstand blade tip incursion and maintain minimal gap clearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If subtractive methods (water jet machining) are used to create abradable surface profile, then abradable surface is produced, but manufacturing cost increases significantly

Engineering Contradiction:

Improveabradable surface qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of subtractively removing material to create the abradable surface profile, the patent applies additive manufacturing to directly deposit the desired surface profile onto the turbine component. This inverts the traditional manufacturing approach from removal to addition, thereby reducing manufacturing cost while maintaining abradable surface quality

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical subtractive machining process (water jet machining) with an additive manufacturing process. This substitution eliminates the need for expensive subtractive manufacturing operations while achieving the same functional result of creating an abradable surface profile

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If simple surface profiles are used, then manufacturing is easier, but complex geometries required for optimal performance cannot be achieved

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidgeometry complexity

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The additive manufacturing process enables variation of geometric parameters (strand heights, patterns, densities) to create complex surface profiles that optimize abradability and clearance control. The process can accommodate any geometric complexity without increasing manufacturing difficulty, as the surface is deposited layer-by-layer according to digital models

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If uniform strand heights are used in mesh structure, then manufacturing is simpler, but optimal abradability and clearance control are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidclearance control precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent creates a mesh structure where individual strands have different heights tailored to local requirements. This local variation in strand height optimizes abradability in different areas and enables precise clearance control between turbine blades and the opposing surface, with each strand's height customized for its specific location's performance needs

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces manufacturing costs and enables the production of complex geometries that would be difficult with subtractive methods, ensuring effective wear of the abradable surface instead of the turbine blade tips, thus maintaining efficiency and longevity of the gas turbine engine.

Implementation Method 1

Laser Powder Forming is an additive manufacturing method which builds up metallic or ceramic parts directly using CAD data by melting a fine powder with a laser beam, layer by layer

Methodology Applied

Scientific EffectLaser melting: Laser

Data Source

PatentUS9644489B1Additive manufacturing of abradable mesh structure on ring segment surface

Publication Date: 2017.05.09 SIEMENS ENERGY INC

AI summary

An abradable turbine component, a method of creating a turbine component with an abradable mesh structure, and a gas turbine engine are provided. The abradable turbine component includes a turbine component surface for coupling to a turbine casing, and a deposited abradable mesh structure coupled to the turbine component surface. The abradable mesh structure includes interlacing strands of material, each strand including a height relative to the turbine component surface. At least two of the plurality of interlacing strands include a height different from each other. The method includes applying a bond coat layer followed by a thermal barrier coating layer. An abradable mesh structure is deposited on top of thermal barrier coating wherein the abradable mesh structure includes interlacing strands of material wherein at least two of the interlacing strands include a height different from each other. A gas turbine engine including the abradable turbine component is also provided.