Gas Turbine Blade Assembly With AM Airfoil and Cast Root
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Solution Overview
Problem
Existing gas turbine engine components, such as turbine blades, are typically cast as single-piece structures, limiting the ability to optimize material properties for strength and cooling efficiency separately, as the airfoil section and root are integrally formed, which can compromise performance and compactness.
Innovation Solution
A method involving separate formation of the pressure and suction side walls using additive manufacturing and the root, platform, and radial supports through casting or forging, allowing for distinct material choices and microchannel cooling, enhancing assembly and joining interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the airfoil section and root are integrally formed as a single-piece structure, then the component has structural simplicity and ease of manufacture, but the ability to optimize material properties for strength and cooling efficiency separately is limited
Solution Approach 1:
The turbine blade is divided into separate airfoil section and root components that are manufactured independently and then joined together. This segmentation allows each part to be optimized separately - the airfoil section can use materials and structures optimized for aerodynamic performance and cooling, while the root can be optimized for structural strength and attachment to the disc.
2Adaptability or versatility
If separate formation of pressure and suction side walls is used, then material properties can be optimized separately for strength and cooling efficiency, but the component complexity increases
Solution Approach 1:
The pressure side wall and suction side wall are joined together to form the complete airfoil section, combining the separately manufactured walls into a unified structural component. This merging maintains the benefits of separate optimization while creating an integrated airfoil structure that functions as a complete unit.
3Ease of manufacture
If traditional single-piece casting is used, then the manufacturing process is simple, but cooling efficiency and compactness are compromised
Solution Approach 1:
Different material properties and structural characteristics are applied to different parts of the turbine blade. The airfoil section incorporates microchannel cooling structures and materials optimized for thermal management, while the root uses materials and structures optimized for mechanical strength. This local quality approach allows each region to have the specific properties needed for its function.
Data Source
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AI summary
One exemplary embodiment of this disclosure relates to a gas turbine engine, including a component having a first portion formed using one of a casting and a forging process, and a second portion formed using an additive manufacturing process.