Assembled Hydrostatic Seal for Complex Geometry and Low Leakage
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Solution Overview
Problem
Existing hybrid seals in gas turbine engines are costly to manufacture using wire EDM and have rough surfaces that require additional processing, limiting design space and increasing production time.
Innovation Solution
The method involves manufacturing multiple separate components using different processes, such as machining and additive manufacturing, and assembling them using techniques like brazing or adhesive bonding to form a hydrostatic advanced low leakage seal, allowing for reduced mass and increased design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wire EDM manufacturing process is used to manufacture hybrid seals, then the seal can be produced with complex internal geometry, but the manufacturing time and cost increase significantly
Solution Approach 1:
The seal is divided into multiple separate components (shoe, base, beams) that can be manufactured independently using different processes. The beams are separate components that connect the shoe to the base, allowing each component to be optimized for its specific manufacturing requirements rather than requiring the entire seal to be made by wire EDM.
Solution Approach 2:
The invention changes the manufacturing parameters by switching from a single process (wire EDM) to multiple processes (additive manufacturing for shoe and base, machining for beams). This allows each component to be manufactured with the most appropriate process for its geometric requirements, reducing overall manufacturing time while maintaining geometric complexity where needed.
2Shape
If wire EDM manufacturing process is used to manufacture hybrid seals, then the seal can be produced with complex internal geometry, but the manufacturing cost increases
Solution Approach 1:
The seal is divided into multiple separate components (shoe, base, beams) that can be manufactured independently using different processes. The beams are separate components that connect the shoe to the base, allowing each component to be optimized for its specific manufacturing requirements rather than requiring the entire seal to be made by wire EDM.
Solution Approach 2:
The invention changes the manufacturing parameters by switching from a single process (wire EDM) to multiple processes (additive manufacturing for shoe and base, machining for beams). This allows each component to be manufactured with the most appropriate process for its geometric requirements, reducing overall manufacturing time while maintaining geometric complexity where needed.
3Shape
If wire EDM is used to cut beams, then the internal geometry can be achieved, but the surface is rough and requires additional processing or limits design space
Solution Approach 1:
Different components have different surface quality requirements. The shoe and base components manufactured by additive manufacturing can have their critical surfaces finished appropriately, while the beams which are machined from plate stock provide inherently better surface quality. This allows local optimization of surface quality where it matters most without requiring the entire seal to be made by wire EDM.
Solution Approach 2:
The invention changes the manufacturing parameters by switching from a single process (wire EDM) to multiple processes (additive manufacturing for shoe and base, machining for beams). This allows each component to be manufactured with the most appropriate process for its geometric requirements, reducing overall manufacturing time while maintaining geometric complexity where needed.
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 and time, while enabling thinner beams that enhance the seal's performance by increasing the resonant frequency and maintaining low leakage, thus improving the seal's operational efficiency and longevity.
Implementation Method 1
The hybrid seal tracking surface is attached to a solid carrier ring via continuous thin beams. These beams enable the low resistance movement of the hybrid seal in a radial direction.
Implementation Method 2
The plurality of separate, independent components are assembled to form the seal... at least one of brazing, adhesive bonding, diffusion bonding, welding
Implementation Method 3
The plurality of separate, independent components are assembled to form the seal... at least one of brazing, adhesive bonding, diffusion bonding, welding
Implementation Method 4
The plurality of separate, independent components are assembled to form the seal... at least one of brazing, adhesive bonding, diffusion bonding, welding
Implementation Method 5
The plurality of separate, independent components are assembled to form the seal... at least one of brazing, adhesive bonding, diffusion bonding, welding
Data Source
AI summary
A method of manufacturing a hydrostatic advanced low leakage seal configured to be disposed between relatively rotatable components is provided. The method includes manufacturing a plurality of separate, independent components of the seal. The method also includes assembling the plurality of separate, independent components to form the seal.