Bi-cast Turbine Rotor Disk with Ceramic Matrix Composite Blades

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Solution Overview

Problem

Conventional dual alloy turbine rotor disks face challenges in high temperatures, are relatively heavy, and costly to manufacture, making them less feasible for modern, efficient, and lightweight gas turbine engines.

Innovation Solution

A bi-cast turbine rotor disk is formed using a superalloy ring and non-metallic ceramic matrix composite blades, where elements from the superalloy are diffused into the ceramic matrix, and the components are bonded together using diffusion bonding or other methods to create a robust and lightweight structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If dual alloy turbine rotor disks are used to withstand high temperatures, then temperature resistance is improved, but weight increases and manufacturing cost increases

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidrotor disk weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent employs a composite structure combining a superalloy ring (for high-temperature resistance) with ceramic matrix composite blades (for lightweight high-temperature performance). This composite approach allows the rotor disk to withstand extreme temperatures while reducing overall weight compared to traditional dual alloy constructions, as ceramic matrix composites have lower density than metal alloys.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different materials to different components based on their specific functional requirements: the ring is made of superalloy to withstand high temperatures and provide structural integrity, while the blades are made of ceramic matrix composite to provide lightweight high-temperature resistance. This localized material selection optimizes the weight-to-performance ratio for each component.

Inventive Principle:

Principle #3Local quality

2Temperature

If dual alloy turbine rotor disks are used to withstand high temperatures, then temperature resistance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidmanufacturing simplicity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The rotor disk is divided into separate components (ring and blades) made from different materials, which are then assembled together. This segmentation allows each component to be manufactured independently using optimized processes for its specific material, simplifying the overall manufacturing compared to creating a single monolithic dual alloy structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By using ceramic matrix composite blades that can be manufactured separately and then attached to the superalloy ring, the patent simplifies the manufacturing process compared to traditional dual alloy rotor disks that require complex hot isostatic pressing or bonding processes to join dissimilar metals.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional alloys are used for turbine rotor disks, then manufacturing cost is reduced, but performance at extreme high temperatures deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidhigh-temperature performance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent uses ceramic matrix composite blades that can be manufactured at lower cost than traditional dual alloy constructions, while achieving superior high-temperature performance. The ceramic matrix composites maintain structural integrity and resistance to thermal degradation at extreme temperatures where conventional alloys would fail.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by using ceramic matrix composites instead of conventional metal alloys for the blades. This material parameter change enables the rotor disk to operate at extreme high temperatures while maintaining cost-effectiveness, as ceramic matrix composites can be manufactured more economically than precision-forged dual alloy structures.

Inventive Principle:

Principle #35Parameter changes

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

The bi-cast turbine rotor disk exhibits improved high-temperature resistance, reduced weight, and lower manufacturing costs, making it suitable for advanced gas turbine engines while maintaining structural integrity.

Implementation Method 1

at least one element from the superalloy of the ring is diffused into the non-metallic ceramic matrix composite of the blade

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS8801388B2Bi-cast turbine rotor disks and methods of forming same

Publication Date: 2014.08.12 HONEYWELL INTERNATIONAL INC

AI summary

A bi-cast turbine rotor disk and method of forming the same are provided. The disk includes a ring and a blade. The ring comprises a superalloy that includes a plurality of elements, and the blade extends from the ring. The blade comprises a non-metallic ceramic matrix composite, and at least one element from the superalloy of the ring is diffused into the non-metallic ceramic matrix composite of the blade.