Airfoil Tip Casting for Precise Cooling Passage Alignment
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Solution Overview
Problem
The assembly of airfoil tip and body portions is laborious and prone to misalignment, leading to increased risk of failure, especially during the manufacturing and repair of turbine blades, due to the need for precise alignment of cooling passages and different material properties between the tip and body portions.
Innovation Solution
A method involving imaging the second end of the body portion to obtain image data, which is used for additively manufacturing a core of the tip portion, forming a casting mold, and casting the tip portion to match the body portion's features, allowing precise alignment and bonding using a bonding material for accurate coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tip portion and body portion are assembled separately to withstand different loads and temperatures, then the airfoil can be optimized for different operating conditions, but the assembly process becomes laborious and time-consuming due to the need for precise alignment of cooling passages and features
Solution Approach 1:
The method performs preliminary actions by creating a digital image of the body portion's second end and using this image data to guide the casting of the tip portion. This preliminary digital documentation and planning enables precise alignment to be achieved during the casting process itself, rather than requiring time-consuming alignment procedures after assembly. The digital image serves as a template that ensures the tip portion will align correctly with the body portion's cooling passages and features from the outset.
2Manufacturing precision
If the tip portion is precisely aligned on the body portion using specialized equipment and meticulous procedures, then alignment accuracy is improved, but the process becomes tedious and production non-friendly
Solution Approach 1:
The invention replaces complex mechanical alignment systems and specialized equipment with a digital imaging and data-driven casting approach. Instead of using physical alignment tools, fixtures, and manual positioning procedures, the method uses digital images and computer-controlled casting processes to achieve precise alignment. This substitution of mechanical systems with digital and computational methods maintains high alignment accuracy while dramatically simplifying the manufacturing process and improving production efficiency.
3Manufacturing precision
If the tip portion is cast to match the body portion's features based on image data, then alignment precision is improved, but the manufacturing process complexity increases due to additively manufacturing a core and forming a casting mold
Solution Approach 1:
The invention introduces a digital image as an intermediary between the body portion and the tip portion casting process. This digital intermediary captures the geometric features of the body portion's second end and translates them into casting instructions for creating the tip portion. The digital image acts as a mediator that bridges the two components, enabling precise alignment without requiring complex direct physical matching or alignment procedures. This intermediary approach simplifies the overall manufacturing process by decoupling the casting operations while maintaining precise alignment through digital guidance.
Data Source
AI summary
A method of fabricating an airfoil includes imaging a second end of the body portion to obtain image data, casting the tip portion utilizing the image data of the second end of the body portion and coupling a first end of the tip portion to the second end of the body portion. One or more features of the tip portion align with one or more features of the body portion. The method also includes additively manufacturing a core of the tip portion utilizing the image data and forming a casting mold about the core. The tip portion is cast in the casting mold. The coupling of the tip portion to the body portion including depositing a bonding material on a first end of the tip portion. An airfoil formed by the method is also disclosed.