Airfoil Preform Support Layout for Edge-Safe Powder Bed Melting
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Solution Overview
Problem
The existing methods of selective melting on a bed of powder for fabricating turbine engine airfoils require removable supports that can lead to shape defects and irregularities during the polishing process due to manual removal of support residues, affecting the aerodynamics of the airfoils.
Innovation Solution
A method is introduced where a flat is fabricated on the airfoil, allowing the removable support to be secured to this flat and a portion of the airfoil's face, which is outside the leading or trailing edge, enabling the support to be spaced apart from the edge, thus preventing direct contact during polishing and reducing the risk of shape defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If removable supports are used to hold airfoils during fabrication, then the airfoils can be properly supported during the selective melting process, but the supports leave residues that require manual polishing and cause shape defects at the leading or trailing edges
Solution Approach 1:
The invention extracts the support function from the edge region and relocates it to the face region. By positioning the removable support on the face outside the leading or trailing edge rather than at the edge itself, the support can be removed without leaving residues that affect edge shape precision, thus resolving the contradiction between support stability and edge shape precision
Solution Approach 2:
The invention introduces an intermediary region (the face area outside the edge) that serves as a buffer zone. The support is positioned in this intermediary region, allowing it to fulfill its support function while being spatially separated from the critical edge region, thereby preventing direct contact during polishing and eliminating shape defects
2Ease of manufacture
If manual polishing is performed to remove support residues, then the supports can be eliminated, but the process is time-consuming and may cause excessive material removal and shape irregularities
Solution Approach 1:
The invention extracts the support residues from the critical edge region and relocates them to the face region. This spatial separation allows for much faster and easier removal of residues using automated or semi-automated processes rather than time-consuming manual polishing, significantly reducing polishing time while maintaining manufacturing ease
Solution Approach 2:
The support structure is designed as a disposable element that is intentionally positioned in a non-critical region where it can be quickly removed and replaced if necessary. The support serves its purpose during fabrication and is then discarded without requiring extensive post-processing, reducing both time and cost
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 ensures a uniform and controlled polishing process, reducing the likelihood of defects and shortening the polishing time, while allowing for systematic adjustment of the airfoil shape without damaging the edges.
Implementation Method 1
a step of selectively melting a portion of the deposited layer of powder by using a heater member
Data Source
AI summary
A method of fabricating an airfoil preform for a turbine engine by selective melting on a bed of powder, the preform including an airfoil and a removable support secured to the airfoil, the airfoil being fabricated layer by layer from a first edge to a second edge of the airfoil, the method including fabricating the removable support and the airfoil, the removable support being for securing to a fabrication platform and to a portion of a face of the airfoil situated near the first edge and facing the fabrication platform. The face of the airfoil facing the fabrication platform includes a flat extending away from the face, the flat being present over a portion of the face that is situated outside the first edge, the support being secured to the flat or both to the flat and to the portion of the face that is situated outside the first edge.