Additive Turbulator Formation on Turbomachine Surfaces

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Solution Overview

Problem

Existing methods for forming turbulators on turbomachine surfaces often involve subtractive processes that result in waste and limited geometrical possibilities, requiring significant time and resources.

Innovation Solution

A method of depositing material onto the turbomachine surface to form turbulators, allowing for the creation of varied geometries and reducing manufacturing time by adding material, rather than removing it, using techniques like MIG welding to form turbulators on compressor, turbine, and combustor surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If subtractive processes are used to form turbulators, then manufacturing precision can be achieved, but material waste increases and manufacturing time extends

Engineering Contradiction:

Improveturbulator geometry precisionVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent inverts the traditional subtractive approach by using additive build-up welding to form turbulators. Instead of removing material to create turbulator geometries, the process deposits weld material (such as austenitic or nickel-based alloys) onto the base metal surface to build up the desired turbulator shapes, thereby eliminating material waste while maintaining manufacturing precision through controlled deposition

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the fundamental parameter of material removal to material addition. By controlling deposition parameters (weld current, travel speed, deposition rate) and using automated welding robots with precise positioning systems, the method achieves accurate turbulator geometries through additive processes, transforming the manufacturing paradigm from subtractive to additive while reducing waste

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If subtractive processes are used to form turbulators, then existing manufacturing methods can be maintained, but manufacturing time increases

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent implements preliminary action by pre-programming the welding robot paths and parameters before production. The automated build-up welding process uses pre-configured deposition patterns and parameters, allowing rapid formation of turbulators without the time-consuming setup and execution required by subtractive methods, thereby increasing manufacturing speed while maintaining process simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical subtractive manufacturing systems with automated welding robots that perform additive build-up welding. This substitution eliminates the need for complex machining operations, tool changes, and manual interventions, streamlining the manufacturing process and significantly reducing production time through automated, continuous deposition

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If diverse turbulator geometries are created, then flow characteristics are enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveturbulator geometry varietyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces dynamics by enabling real-time adjustment of welding parameters and robot motion paths during the build-up process. The automated system can dynamically modify deposition rates, travel speeds, and layer configurations to create various turbulator geometries (such as ribs, protrusions, or complex three-dimensional shapes) without requiring different tooling or fixtures, thereby achieving geometry versatility while maintaining manufacturing simplicity

Inventive Principle:

Principle #15Dynamics

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 waste and manufacturing time while enabling the creation of turbulators with diverse geometries and heat transfer characteristics, enhancing flow and operational characteristics of turbomachines.

Implementation Method 1

A method of depositing material onto the turbomachine surface to form turbulators... using techniques like MIG welding

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3015211B1Method of forming tubulators on a turbomachine surface using build-up welding and corresponding turbomachine

Publication Date: 2017.12.13 GENERAL ELECTRIC CO

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AI summary

A method of forming a plurality of turbulators on a turbomachine surface (50) includes depositing a first portion of material (90) on the turbomachine surface (50) forming a first portion of the plurality of turbulators, adding additional material (94) to the first portion, and establishing a desired dimension of the plurality of turbulators.