One-Piece Annular Metal Part with Composite Reinforcing Insert
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Solution Overview
Problem
Current methods for manufacturing one-piece annular metal parts with composite reinforcing inserts are costly and time-consuming, requiring multiple operations and machining steps, especially when producing turbine engine rotor disks, which incur high production costs and weight due to the need for complex block and flange designs and extensive machining.
Innovation Solution
A method involving the formation of a blank by layering metal wire and coated fibers around a rotating mandrel, followed by hot isostatic pressing and minimal machining to create a one-piece annular metal part with a reinforcing insert, eliminating the need for complex block and flange designs and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional forging and machining operations are used to manufacture one-piece annular metal parts, then the parts achieve required mechanical properties and structural integrity, but the production cost and weight increase significantly
Solution Approach 1:
The patent applies composite materials by combining metal wires with ceramic fibers (such as silicon carbide) to create a hybrid structure. The ceramic fibers provide high tensile strength (4000 MPa) while the metal matrix (titanium alloy) provides ductility and bonding. This composite approach reduces part weight while maintaining or improving mechanical properties compared to traditional monolithic metal parts.
2Reliability
If traditional forging and machining operations are used to manufacture one-piece annular metal parts, then the parts achieve required structural integrity, but the production cost increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the complex annular geometry and integrating the composite reinforcing insert into a single monolithic structure through controlled deposition and hot isostatic pressing. This eliminates the need for subsequent expensive machining operations to create complex shapes and assemble multiple components, thereby reducing production cost while maintaining structural integrity.
3Strength
If traditional block and flange designs are used to manufacture turbine engine rotor disks, then the parts achieve required mechanical properties, but the production time and costs increase
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct functional zones: a metal matrix providing ductility and bonding, and ceramic fiber insertions providing high-strength reinforcement in specific regions. This segmented approach allows optimization of material properties in different areas of the rotor disk, achieving required mechanical properties while reducing production time through direct formation without multiple assembly steps.
4Weight of moving object
If composite materials with ceramic fibers are used to reduce part weight, then the weight decreases, but the manufacturing complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing traditional mechanical manufacturing processes (forging, machining, assembly) with a direct deposition and hot isostatic pressing process. The composite materials are deposited in their final configuration and then densified in-situ, eliminating the need for complex mechanical assembly operations and reducing manufacturing complexity despite the advanced material system.
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 method enables the production of lightweight, cost-effective one-piece annular metal parts with improved mechanical properties by directly forming a homogeneous metal part from windings of metal wire and composite fibers, reducing production time and costs while maintaining structural integrity.
Implementation Method 1
placing the blank in a receiving tool, and applying a hot isostatic pressing treatment to the blank
Data Source
AI summary
A method for manufacturing a one-piece annular metal part having a reinforcing insert of composite material includes forming a blank of the part by superimposing, around a rotating cylindrical mandrel, layers of metal wire and layers of coated fiber, the layers of coated composite fiber being arranged in the blank according to the positioning of the insert in the part; placing the blank in a receiving tool, and applying a hot isostatic pressing treatment to the blank; and extracting the treated blank from the receiving tool and, as required, machining the treated blank to obtain the one-piece annular metal part having a reinforcing insert.