Bathtub Tip Blade Partitioning via CLAD Without Complex Core Slots
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Solution Overview
Problem
The manufacturing of turbine engine blades with complex bathtub tip geometries is hindered by the need for additional ribs or partitions, which complicates the development of the second core and increases rejection rates due to manufacturing limitations, particularly the orientation of slots which prevent proper stripping during core production.
Innovation Solution
Employing Additive Manufacturing methods, such as Direct Laser Additive Manufacturing (CLAD), to deposit metal powder and create inner partitions on the bathtub tip bottom, followed by machining to achieve the desired shape and improve aerodynamics without altering the core moulding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ribs or partitions are added to optimise cooling and aerodynamics in the bathtub tip, then cooling efficiency and aerodynamics are improved, but the development of the second core is significantly complicated and rejection rate increases
Solution Approach 1:
The method prepares the bathtub tip surface beforehand by creating a recess or cavity structure before depositing the rib or partition material. This preliminary preparation allows the subsequent additive manufacturing process to easily form the desired rib geometry without complicating the core mould design, as the core simply needs to define the initial bathtub tip shape rather than incorporating complex rib features.
Solution Approach 2:
The invention introduces an intermediary process (additive manufacturing/deposition process) between the core removal and final rib formation. Instead of incorporating ribs directly into the core design, the method uses a deposition process that adds material after core removal, thereby avoiding the complexity of designing cores with internal rib structures while still achieving the desired cooling and aerodynamic features.
2Shape
If slots for ribs are provided at the end of the second core, then rib structures can be formed, but the slots create undercut areas that prevent stripping the core during manufacture
Solution Approach 1:
The method prepares the bathtub tip surface beforehand by creating a recess or cavity structure before depositing the rib or partition material. This preliminary preparation allows the subsequent additive manufacturing process to easily form the desired rib geometry without complicating the core mould design, as the core simply needs to define the initial bathtub tip shape rather than incorporating complex rib features.
Solution Approach 2:
Instead of forming ribs by removing material or creating slots in the core (traditional approach), the invention inverts the process by first creating the bathtub tip shape with the core, removing the core, and then adding material through deposition to form the ribs. This inversion eliminates the undercut problem entirely, as the deposition process can create any geometry without being constrained by core stripping requirements.
3Shape
If the second core is manufactured in several ceramic sections assembled by gluing, then complex internal shapes can be achieved, but manufacture is significantly complicated and rejection rate increases due to insufficient robustness
Solution Approach 1:
The method prepares the bathtub tip surface beforehand by creating a recess or cavity structure before depositing the rib or partition material. This preliminary preparation allows the subsequent additive manufacturing process to easily form the desired rib geometry without complicating the core mould design, as the core simply needs to define the initial bathtub tip shape rather than incorporating complex rib features.
Solution Approach 2:
The invention introduces an intermediary process (additive manufacturing/deposition process) between the core removal and final rib formation. Instead of incorporating ribs directly into the core design, the method uses a deposition process that adds material after core removal, thereby avoiding the complexity of designing cores with internal rib structures while still achieving the desired cooling and aerodynamic features.
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
Enables the production of a variety of internal shapes at the bathtub tip without increasing rejection rates, enhancing cooling efficiency and aerodynamics while maintaining the integrity of the moulding process.
Implementation Method 1
a step of adding metal to the bottom of the bathtub tip by means of Additive Manufacturing, by adding metal, in particular, by depositing metal powder
Data Source
AI summary
The invention relates to a method for manufacturing a turbine engine blade (16) including an active-surface wall (17) and a passive-surface wall (18) separated from one another, this blade (16) including a tip that has a closing wall grouping together the active-surface (17) and passive-surface (18) walls in the region of this tip to define the bottom (23) of a bathtub tip shape located at the tip of the blade, the method comprising a moulding step implementing a core defining the bathtub tip shape. According to the invention, there is a step of adding metal to the bottom (23) of the bathtub tip by means of a Direct Laser Additive Manufacturing (CLAD) method, to deposit material onto the bottom of the bathtub tip to form therein an inner partition (28) supported by the bottom thereof (23).