Additive Manufactured Abradable Seal for Turbine Duct Leakage Control
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Solution Overview
Problem
The existing abradable seals in gas turbine engines, typically brazed onto components, are fragile and costly to manufacture, with inconsistent joint shapes due to brazing processes, which can lead to damage and inefficiencies in sealing performance.
Innovation Solution
The integration of abradable seals within the body of components using additive manufacturing, where the seals are built layer-by-layer with uniform joints and made from the same material as the body, reducing the need for post-building modifications and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abradable seals are brazed onto components, then sealing performance is achieved, but manufacturing cost and time increase
Solution Approach 1:
The abradable seal is merged with the body to form a single integral component through additive manufacturing. The seal is built layer-by-layer directly onto the sealing portion of the body, eliminating the need for separate brazing operations. This integration reduces manufacturing steps, lowers cost, and maintains reliable sealing performance through uniform joints between the seal and body.
Solution Approach 2:
The sealing portion is prepared in advance on the body during the additive manufacturing process, with the abradable seal being built directly onto it in the same manufacturing run. This preliminary preparation eliminates the need for post-manufacturing brazing operations, significantly reducing manufacturing time and cost while ensuring proper seal placement.
2Reliability
If abradable seals are brazed onto components, then sealing function is achieved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process merges the seal and body into a single additive manufacturing operation. The seal is constructed layer-by-layer directly on the sealing portion of the body, consolidating multiple manufacturing steps into one process. This reduces manufacturing complexity while maintaining the sealing function through integral construction with uniform joints.
Solution Approach 2:
The complex brazing process is extracted and replaced with the simpler additive manufacturing process. By taking out the separate brazing operation and replacing it with direct layer-by-layer construction, the manufacturing complexity is reduced while the sealing function is maintained through the integral seal structure.
3Reliability
If abradable seals are brazed onto components, then sealing is achieved, but joint uniformity deteriorates
Solution Approach 1:
The seal and body are merged into a single integral structure through additive manufacturing. The layer-by-layer construction process ensures uniform joints between the seal and body, as each layer is precisely deposited and bonded to the previous layer. This eliminates the joint variability inherent in brazing processes while maintaining effective sealing.
Solution Approach 2:
The manufacturing approach changes from thermal brazing to additive manufacturing, fundamentally altering the joining parameters. The layer-by-layer deposition process provides precise control over joint formation, ensuring uniformity that cannot be achieved through brazing. This parameter change improves manufacturing precision while maintaining sealing reliability.
4Reliability
If abradable seals are made fragile and brazed, then sealing function is achieved, but durability decreases
Solution Approach 1:
The seal is merged with the body as an integral component, eliminating the weak interface created by brazing. The additive manufacturing process creates a strong, uniform bond between the seal and body, improving durability. The seal maintains its sealing function while being more robust and less prone to damage during installation and operation.
Solution Approach 2:
The invention moves away from creating fragile, replaceable seals toward a durable, long-lasting integral seal structure. By making the seal an integral part of the body with uniform joints, the design eliminates the need for frequent replacement, improving overall system durability while maintaining the sealing function.
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 results in faster manufacturing, reduced weight and cost, and improved sealing performance with deeper rub depths, minimizing leakage while maintaining seal integrity during operation.
Implementation Method 1
selectively sintering a first layer of pulverulent material within a frame to make a partially built component; lowering the partially built component; adding a second layer of pulverulent material on top of the partially built component; and selectively sintering the second layer of pulverulent material to the partially built component
Data Source
AI summary
A method of making a component includes creating a computer file defining the component in layers, the component including: a body including a sealing portion; and an abradable seal extending from the sealing portion; and building the component using an additive manufacturing process that builds the component on a layer-by-layer basis such that the abradable seal is integral to the body.