Airfoil Assembly Microstructure Split for Lower-Cost Fabrication
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Solution Overview
Problem
The fabrication of airfoil assemblies in gas turbine engines is costly due to limitations in existing casting techniques, which struggle with achieving desired microstructures in complex geometries, leading to high rejection rates and increased processing costs.
Innovation Solution
A multi-technique fabrication process is employed, where one technique, such as investment casting, is used for airfoils with a single-crystal microstructure, and another technique, like additive fabrication, is used for platforms with different microstructures, allowing for the selection of varying materials and microstructures for each component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If investment casting is used for airfoils with single-crystal microstructure, then the strength and microstructural quality are improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The airfoil assembly is divided into two distinct sections: airfoils with single-crystal microstructure and platforms with different microstructures. Each section is manufactured using the most appropriate technique for its specific requirements, allowing optimization of both strength and cost.
Solution Approach 2:
Different microstructures are applied to different parts of the assembly based on functional requirements. The airfoils require high-strength single-crystal microstructure, while the platforms can use cost-effective alternative microstructures.
2Manufacturing precision
If traditional casting techniques are used for complex geometries, then the manufacturing process is simpler, but the microstructural quality and productivity decrease
Solution Approach 1:
The patent combines investment casting and additive fabrication into a hybrid manufacturing process. Investment casting provides precise single-crystal microstructure for airfoils, while additive fabrication enables rapid prototyping and complex geometry construction for platforms.
3Adaptability or versatility
If additive fabrication is used for platforms, then the design flexibility and ease of manufacture are improved, but the material strength may be reduced
Solution Approach 1:
The patent utilizes different processing parameters and techniques for different sections. Additive fabrication parameters are optimized for platform geometries, while investment casting parameters are optimized for airfoil microstructures, allowing each section to achieve its required properties.
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 manufacturing costs, increases design flexibility, and adaptability, while eliminating the need for costly tooling and minimizing manufacturing variations, enabling the combination of high-strength single-crystal airfoils with the flexibility of additive fabrication for constructing airfoil platforms.
Implementation Method 1
additive fabrication, is used for platforms with different microstructures
Implementation Method 2
airfoils with a single-crystal microstructure
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
An article includes a body that has a first section and a second section bonded with the first section. The first section is formed with a first material that has a first microstructure and the second section is formed of a second material that has a second, different microstructure.