Gas Turbine Airfoil Forming with Controlled Heating and Cooling
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Solution Overview
Problem
Existing methods for forming gas turbine engine components, such as hollow fan blades, face challenges in achieving precise deformation and cooling processes while maintaining structural integrity and reducing weight.
Innovation Solution
A method involving attaching a cover skin to an airfoil body, heating the assembly to a predefined temperature, deforming it between dies, and then cooling it in a controlled manner to establish a temperature gradient, while allowing axial and rotational movements to achieve a desired stagger angle and internal cavity formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the airfoil is heated to high temperature for deformation, then the material becomes more formable and easier to deform, but the structural integrity may be compromised and grain growth may occur
Solution Approach 1:
The patent applies solution heat treatment at controlled temperatures (900-1100°C) to change the material parameters of the superalloy airfoil, making it more formable during hot deformation while maintaining structural integrity through precise temperature control and subsequent controlled cooling rates
Solution Approach 2:
The patent utilizes phase transition characteristics of superalloys during heating and cooling cycles. The material undergoes phase changes at specific temperature ranges that enable deformation, followed by controlled cooling to stabilize the microstructure and prevent excessive grain growth
2Productivity
If rapid cooling is applied after deformation, then productivity increases and cycle time is reduced, but deformation may occur and shape precision may be compromised
Solution Approach 1:
The patent employs dynamic cooling rate adjustment during the cooling process. The cooling rate is optimized at different stages: initial rapid cooling to room temperature for productivity, followed by controlled cooling to prevent deformation and maintain shape precision of the airfoil
3Shape
If the airfoil is heavily deformed to achieve desired geometry, then the final shape is achieved, but residual stresses increase and structural integrity deteriorates
Solution Approach 1:
The patent changes material parameters through solution heat treatment before deformation, making the superalloy more ductile and easier to deform into the desired complex geometry while reducing the magnitude of residual stresses through controlled thermal processing
4Device complexity
If the airfoil is cooled uniformly, then the process is simple and fast, but temperature gradients are insufficient for optimal material properties
Solution Approach 1:
The patent applies different cooling rates to different regions or stages of the cooling process. Controlled cooling rates are used during critical phases to establish appropriate temperature gradients that optimize microstructure stability and material properties, while maintaining overall process simplicity
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 method enhances the structural integrity and reduces weight of the components by minimizing deformation and ensuring precise shape retention, while also improving cooling efficiency through controlled temperature gradients.
Implementation Method 1
heating the airfoil body to a first predefined temperature threshold between the first and second dies
Implementation Method 2
cooling the airfoil in the cooling chamber to a second predefined temperature threshold less than the first predefined temperature threshold
Implementation Method 3
improving cooling efficiency through controlled temperature gradients
Data Source
Figure 1
Figure 2
Figure 3~3B
AI summary
A method of forming a gas turbine engine component (260) according to an example of the present disclosure includes, among other things, attaching a cover skin (270) to an airfoil body (268), the airfoil body (268) and the cover skin (270) cooperating to establish pressure and suction sides (PS, SS) of an airfoil (261), positioning the airfoil (261) between first and second dies (287-1, 287-2) of a deforming station (284-2), heating the airfoil body (268) to a first predefined temperature threshold between the first and second dies (287-1, 287-2), and moving the first die (287-1) relative to the second die (287-2) to hold the airfoil (261) between the first and second dies (287-1, 287-2) subsequent to the heating step, and then deforming the airfoil (261) between the first and second dies (287-1, 287-2).