Additive Manufacturing Gas Turbine Components
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Solution Overview
Problem
Components in gas turbine engines, particularly those operating at high temperatures and pressures, face challenges in achieving high fatigue and creep resistance due to process constraints and variables affecting the microstructure-properties relationship, especially in multi-phase, highly alloyed materials.
Innovation Solution
A method of additively manufacturing components using a powder-bed fusion process, where the first layer of powdered material is compacted to a second thickness between 20 and 40 µm, and subsequent layers are compacted to achieve a thickness between 40 and 60% of the previous layer, with specific parameters for laser power, scan speed, and offset settings to optimize microstructure and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing processes are used, then component geometry can be achieved, but microstructure uniformity and mechanical properties deteriorate due to process constraints and variables
Solution Approach 1:
The patent applies parameter changes by systematically optimizing multiple process parameters including laser power (200-500W), scan speed (1000-5000mm/s), layer thickness (20-40μm), and hatch spacing (30-100μm) to achieve uniform microstructure and high mechanical properties while managing process complexity
2Productivity
If high laser power is used to improve sintering efficiency, then productivity increases, but microstructure quality deteriorates due to excessive heat input
Solution Approach 1:
The patent resolves this contradiction by implementing specific parameter ranges: laser power between 200-500W and scan speed between 1000-5000mm/s, which balance sintering efficiency with microstructure quality by controlling heat input and cooling rates to achieve uniform grain structure
Solution Approach 2:
The patent applies dynamics by using adaptive scan strategies that adjust laser parameters based on local geometric features, allowing high productivity in simple areas while maintaining microstructure quality in complex regions through dynamic parameter modification
3Productivity
If rapid scanning is used to increase build speed, then productivity improves, but layer bonding quality deteriorates due to insufficient energy input
Solution Approach 1:
The patent maintains layer bonding strength at high build speeds by optimizing the power-speed relationship, keeping laser power between 200-500W and scan speed between 1000-5000mm/s to ensure sufficient energy input for complete layer fusion while maintaining rapid production rates
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
The method results in components with improved fatigue and creep resistance, characterized by high density (>99%), uniform grain size (40-60 µm), and equiaxed grain shapes, which are maintained across both thick and thin areas of the component, thereby enhancing homogeneity and mechanical properties.
Implementation Method 1
the software program directs a laser to selectively sinter the powdered material layers into unitary solid layers
Implementation Method 2
the compacting step compacts the first layer of powdered material to a second thickness
Implementation Method 3
the component is subjected to heat treatment, performed in a hot isostatic press
Implementation Method 4
the component is subjected to heat treatment, performed in a hot isostatic press
Data Source
Figure 1A~5
Figure 3A~3B
AI summary
An example method of making a component includes providing a digital model of a component to software, the software operable to slice the model into layers and raster each layer into segments, the segments delineated by raster lines. The method further includes depositing a layer of powder onto a platform, compacting the layer of power into a compacted layer, sintering the compacted layer along lines corresponding to the raster lines using a laser, wherein the laser operates at a first power and a first scan speed, the first power being between about 200 and 230 W, then sintering the compacted layer along a perimeter of the compacted layer using the laser to form a unitary layer, wherein the laser operates at a second power and a second scan speed, the second power being between about 100 and 200 W. An apparatus for making a component is also disclosed.