Gas Turbine Airfoil Segments Bonded by Diffusion Joints
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Solution Overview
Problem
Current gas turbine engine airfoils face challenges in achieving optimal structural integrity and thermal resistance due to limitations in material selection and bonding techniques, particularly at the leading edge where high stresses and thermal conditions prevail.
Innovation Solution
The use of diffusion joints bonding different base-metal metallic alloys or ceramic-based materials at the leading edge of airfoils, with specific configurations such as radial segmentation and overlapping expansion joints, to enhance structural support and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single material is used for the entire airfoil, then manufacturing is simpler and cost is lower, but the airfoil cannot optimize structural integrity and thermal resistance at different locations simultaneously
Solution Approach 1:
The airfoil is divided into multiple segments (first airfoil segment and second airfoil segment) that can be made from different materials. These segments are joined together to form the complete airfoil structure, allowing each segment to be optimized for its specific functional requirements while maintaining overall structural integrity.
Solution Approach 2:
Different materials are selected for different segments of the airfoil based on local requirements. For example, the leading edge segment may use materials with superior thermal resistance properties, while other segments use materials optimized for structural strength or weight considerations, achieving localized optimization throughout the airfoil structure.
2Reliability
If traditional bonding techniques are used to join different materials, then manufacturing is easier, but the bond strength and reliability at the joint are insufficient under high stress and thermal conditions
Solution Approach 1:
A diffusion joint is introduced as an intermediary bonding mechanism between the first and second airfoil segments made of different materials. This diffusion joint creates a metallurgical bond through atomic diffusion across the interface, providing superior bond strength and reliability compared to traditional mechanical or adhesive bonding techniques, while still being manufacturable through controlled thermal processing.
3Strength
If the airfoil is designed with complex material configurations for optimal performance, then structural integrity and thermal resistance improve, but manufacturing precision requirements increase
Solution Approach 1:
The airfoil segments are pre-formed with their specific material compositions and geometries before the diffusion bonding process. This preliminary preparation allows for precise control of material properties and joint geometry, reducing the precision requirements during the final bonding operation while ensuring optimal structural integrity and thermal resistance performance.
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 improves the structural integrity and thermal resistance of gas turbine engine airfoils by allowing for localized material selection and complex design features, enhancing durability and efficiency under varying operating conditions.
Implementation Method 1
an airfoil including first and second structural airfoil segments that are bonded to each other in at least one diffusion joint
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
A component includes a component body that is configured for use in a gas turbine engine. The component body includes first and second structural segments that are bonded to each other in at least one diffusion joint. The first and second structural segments are formed of, respectively, first and second materials. The first and second materials are different base-metal alloys, a metallic alloy and a ceramic-based material, or ceramic-based materials that differ by at least one of composition and microstructure.