Airfoil Tip Abrasive Grit Embedding With Laser Melt Pools
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Solution Overview
Problem
The existing methods for applying abrasive grit to gas turbine airfoils, such as electroplating, are time-consuming, costly, and inefficient, particularly when using cubic Boron Nitride (cBN) abrasives, which require multiple operations and masking processes.
Innovation Solution
A method involving the use of a laser or magnetic induction energy source to create a melt pool on the airfoil tip, where abrasive grit is applied and locked into place using a computer-aided manufacturing system, allowing for precise control of grit concentration and pattern, reducing pre and post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electroplating process is used to attach abrasive grit, then wear resistance of airfoil is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces the electroplating process with a laser-based direct embedding process. The laser melts the substrate surface and simultaneously embeds the abrasive grit particles into the molten pool, eliminating the need for electroplating chemistry and masking steps. This substitution of mechanical/thermal process for electrochemical process resolves the time and complexity contradiction.
Solution Approach 2:
The laser process performs multiple operations simultaneously: it melts the substrate, positions the abrasive grit, and embeds it in one continuous action. The preliminary heating and melting of the surface prepares it for immediate grit embedding without requiring separate masking and plating steps, thus reducing manufacturing time while maintaining wear resistance.
2Strength
If electroplating process is used to attach abrasive grit, then wear resistance of airfoil is improved, but process complexity and cost increase
Solution Approach 1:
The patent merges multiple separate operations (masking, electroplating, mask removal, surface preparation) into a single laser-based embedding process. The laser system simultaneously performs heating, melting, and grit embedding in one integrated operation, significantly reducing process complexity and equipment requirements while achieving the same wear resistance improvement.
Solution Approach 2:
The patent extracts and eliminates the masking step entirely from the process sequence. By using laser direct embedding, there is no need to apply masks to protect areas where plating should be avoided, as the laser can be precisely controlled to embed grit only where needed. This extraction of the masking operation simplifies the overall process.
3Loss of time
If laser is used to embed abrasive grit, then manufacturing time is reduced, but energy consumption increases
Solution Approach 1:
The laser energy is concentrated and applied only to the specific local areas where abrasive grit embedding is required, rather than heating the entire airfoil component. This localized energy application minimizes total energy consumption while achieving rapid processing and reduced manufacturing time compared to bulk heating methods.
Solution Approach 2:
The laser operates in a pulsed or periodic manner, delivering energy in controlled intervals to melt and embed grit particles. This periodic energy delivery allows for efficient energy utilization, preventing excessive heat accumulation and reducing overall energy consumption while maintaining fast processing speeds.
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 enhances the wear resistance of airfoil tips by efficiently embedding abrasive grit in a predetermined pattern, minimizing processing time and costs while ensuring strong bonding and uniform temperature distribution, thus improving the robustness of the airfoil-seal interface.
Implementation Method 1
utilizing an energy source, such as a laser or magnetic induction, to melt a thin melt pool layer of the airfoil tip
Implementation Method 2
utilizing an energy source, such as a laser or magnetic induction, to melt a thin melt pool layer of the airfoil tip
Implementation Method 3
The melt pool layer is then solidified and locks the abrasive grit into place
Data Source
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AI summary
A method for forming an abrasive surface (110) includes utilizing an energy source (210) to form a melt pool layer (500) in a substrate (96) and applying abrasive grit (112) into the melt pool layer (500). Another method for forming an abrasive surface (110) includes applying an abrasive grit (112) to a substrate (96) and utilizing an energy source (210) to form a melt pool layer (500) in the substrate (96) without disturbing the abrasive grit (112) such that the abrasive grit (112) becomes embedded in the melt pool layer (500).