Additive Manufacturing Nested Component for Thermal Conductivity and Strength
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Solution Overview
Problem
Materials with high thermal conductivity, such as copper, often lack structural strength and resistance to harsh operational conditions, particularly at elevated temperatures, making them unsuitable for thermally loaded engine components like gas turbine engines.
Innovation Solution
A component comprising a first material providing structural strength and a second material with high thermal conductivity, where the second material is enclosed within the first material through an additive manufacturing process, eliminating the need for bonding and allowing for the use of incompatible materials, with the second material potentially having a higher thermal expansion coefficient for a tighter fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If materials with high thermal conductivity (e.g., copper) are used, then thermal conductivity is improved, but structural strength and resistance to harsh operational conditions at elevated temperatures deteriorate
Solution Approach 1:
The patent employs a composite structure consisting of an inner core made from high thermal conductivity material (such as copper) and an outer shell made from high temperature resistant material (such as nickel base alloy). This composite configuration allows the component to simultaneously achieve high thermal conductivity from the core material and structural strength at elevated temperatures from the shell material, effectively resolving the contradiction between thermal performance and mechanical strength.
2Use of energy by stationary object
If materials with high thermal conductivity are used, then heat distribution is improved, but reliability under harsh operational conditions deteriorates
Solution Approach 1:
The composite structure combines a core material optimized for heat distribution (high thermal conductivity) with a shell material optimized for reliability under harsh conditions (high temperature resistance, oxidation resistance). This allows the component to achieve excellent heat distribution while maintaining high reliability in thermally loaded environments such as gas turbine engines.
3Ease of manufacture
If bonding or welding is used to join different materials, then component assembly is achieved, but compatibility and reliability at elevated temperatures deteriorate
Solution Approach 1:
The patent utilizes a nested configuration where the inner core material is completely enclosed within the outer shell material, forming a form-fit structure. This nesting approach eliminates the need for bonding or welding between dissimilar materials, avoiding the reliability issues associated with joining incompatible materials at elevated temperatures. The components are assembled through interference fit or mechanical retention mechanisms that maintain integrity under thermal loading.
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 solution achieves a component with enhanced thermal conductivity and structural integrity at high temperatures, ensuring efficient heat distribution and coolant usage, while allowing for the use of materials that would otherwise be incompatible or unreliable at elevated temperatures.
Implementation Method 1
a method for producing the component does not involve assembling the first member embracing the second member in joining two or more distinct pieces. The first member is said to be seamless or monolithic or one-piece. This is achieved in manufacturing the first member by an additive manufacturing process
Implementation Method 2
In another aspect of the disclosure the second material may be chosen to have a higher thermal expansion coefficient than the first material. This would serve to effect an additional tight fit of the second member within the first member at elevated operational temperatures.
Implementation Method 3
As noted and implied above, it might be found beneficial if the second material is chosen to have a higher thermal conductivity than the first component. In another aspect of the disclosure the second material may be chosen to have a higher thermal conductivity than the first component. This would serve to enhance heat conduction from the component to the coolant side and consequently to the coolant.
Data Source
Figure 1a~3
Figure 4~5
AI summary
A component (1) is disclosed, the component comprising a first material and a second material, wherein a second member (4) made from the second material is embraced by a first member (10) made from the first material. Further, a method is disclosed for manufacturing said component, the method comprising applying an additive manufacturing process, building up a first member (10) from a first material by the additive manufacturing process, and adding a second member (4) made from a second material during the additive manufacturing process and adding further first material (12) to the first member thus embracing the second member.