Airfoil Bonding Mold Tool for Camber and Twist Control
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Solution Overview
Problem
Current methods for bonding airfoil components in gas turbine engines result in increased variability due to reliance on uniform bond pressure, leading to inconsistencies in camber and other airfoil parameters, which affects flow characteristics and flow capacity, resulting in material waste and increased costs.
Innovation Solution
A mold tool system that supports airfoil assemblies during bonding, applying heat and pressure while maintaining preselected airfoil parameters such as camber, twist, and angles, using a vacuum sealing sheet to ensure an airtight seal and align components accurately, thereby reducing geometric variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform bond pressure from autoclave is used to bond airfoil components, then bonding process is simple, but manufacturing precision of airfoil geometry deteriorates
Solution Approach 1:
A mold tool is introduced as an intermediary device between the autoclave and the airfoil assembly. The mold tool includes a cavity that receives the airfoil assembly and applies localized pressure and heat through its surfaces, enabling precise geometric control while maintaining bonding simplicity. The mold tool acts as a mediator that translates the general autoclave environment into specific, controlled bonding conditions.
Solution Approach 2:
The mold tool changes the pressure and heat distribution parameters from uniform (autoclave-wide) to localized (airfoil-specific). By designing the mold tool cavity with specific geometries that complement desired airfoil parameters (camber, twist, angles), the system achieves precise geometric control through parameter modification rather than relying on uniform autoclave conditions.
2Ease of operation
If airfoil components are bonded in free unrestrained state, then ease of assembly is improved, but manufacturing precision of airfoil parameters deteriorates
Solution Approach 1:
The mold tool cavity is pre-configured with the exact geometry of the desired airfoil assembly before bonding begins. Components are placed in the mold tool in their natural state, and the mold tool's pre-formed cavity automatically positions and restrains them to achieve the target geometry. This preliminary configuration of the mold tool eliminates the need for complex pre-alignment procedures while ensuring precision.
Solution Approach 2:
The mold tool transforms the assembly process by changing the spatial parameters of component placement. Instead of requiring precise manual positioning of each component, the mold tool cavity provides physical constraints that automatically establish the correct relative positions, orientations, and geometries of all airfoil components during bonding.
3Productivity
If increased variability in bonded product is accepted, then productivity is improved, but reliability of airfoil performance deteriorates
Solution Approach 1:
The mold tool serves as a quality control intermediary that ensures each airfoil assembly meets geometric specifications before leaving the bonding process. By maintaining consistent geometric parameters through the mold tool's precision cavity, the system produces reliable products at high volume without requiring post-bonding inspection and rework, thus maintaining productivity while improving reliability.
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 mold tool system significantly reduces assembly variation and post-inspection failures by ensuring consistent airfoil geometry and flow capacity, minimizing material waste and costs.
Implementation Method 1
The bonding process may comprise an application of heat and pressure to the airfoil assembly
Implementation Method 2
The bonding process may comprise an application of heat and pressure to the airfoil assembly
Implementation Method 3
A vacuum sealing sheet may be configured to cover the airfoil assembly. A sealing member may be configured to form an airtight seal between the vacuum sealing sheet and the mold tool
Data Source
AI summary
An airfoil bonding system may comprise a mold tool configured to support an airfoil assembly during a bonding process. The bonding process may include applying heat and pressure to the airfoil assembly. A surface of the mold tool may complement a preselected airfoil parameter. The mold tool may maintain the airfoil assembly in the preselected airfoil parameter during the application of heat and pressure to the airfoil assembly.