Binder-Jet Erosion Shields for Crack-Resistant Turbine Blades

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for manufacturing erosion shields for turbine blades are time-consuming, costly, and prone to cracking, with repair processes taking up to six months and requiring extensive inventory storage, while existing erosion shields suffer from mechanical and thermal stress-induced damage.

Innovation Solution

Utilizing binder jet additive manufacturing (BJAM) to produce erosion shields with an equiaxed grain structure and minimal residual stress, allowing for on-demand production of erosion-resistant materials like cobalt-chromium alloys directly on turbine blades, reducing lead times to two weeks and minimizing inventory costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional casting or forging methods are used to manufacture erosion shields, then the shields can be produced with erosion-resistant material, but the manufacturing process is time-consuming and prone to cracking

Engineering Contradiction:

Improvecrack resistanceVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the manufacturing parameters by transitioning from conventional casting or forging to binder jet additive manufacturing followed by sintering. This process transformation eliminates the cracking issues associated with conventional methods while reducing manufacturing time from months to weeks, directly resolving the technical contradiction between reliability and productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical casting or forging processes with an additive manufacturing system that uses binder jetting and sintering. This substitution eliminates the mechanical stresses and thermal shocks that cause cracking in conventional methods, while the automated additive process significantly reduces manufacturing time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conventional manufacturing methods are used for erosion shields, then the shields can be produced, but extensive inventory storage is required and repair processes take up to six months

Engineering Contradiction:

Improverepair timeVSAvoidinventory storage

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent enables on-demand production of erosion shields through additive manufacturing, eliminating the need for pre-stored inventory. Shields can be manufactured when needed, transforming the logistics from maintaining extensive inventory to producing components just-in-time, thereby reducing storage requirements while accelerating repair timelines from six months to two weeks

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The additive manufacturing system allows each location to produce its own erosion shields as needed, eliminating dependence on centralized inventory storage and distribution. This self-service capability enables rapid local production, reducing both inventory requirements and repair times

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If conventional casting or forging methods are used to produce erosion shields, then the shields can be manufactured, but the process is costly and time-consuming

Engineering Contradiction:

Improvemanufacturing costVSAvoidlead time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent transforms the manufacturing parameters from conventional high-cost, long-duration casting or forging processes to additive manufacturing with binder jetting and sintering. This parameter change reduces both manufacturing cost and lead time simultaneously, addressing the technical contradiction between ease of manufacture and loss of time

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 BJAM process enables rapid, cost-effective production of erosion shields with uniform properties and reduced cracking risk, enhancing the lifespan and performance of turbine blades by providing efficient erosion protection.

Implementation Method 1

printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material

Methodology Applied

Scientific EffectSelective deposition: Deposition (physical)

Implementation Method 2

sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS12571311B2Erosion-shielded turbine blades and methods of manufacturing the same

Publication Date: 2026.03.10 GE INFRASTRUCTURE TECH LLC

AI summary

A method of manufacturing an erosion-shielded turbine blade includes providing a turbine blade for use with a rotary machine. The turbine blade includes an airfoil extending between a root and a tip. The airfoil includes a pressure side and an opposite suction side, and each of the pressure and suction sides extends between a leading edge and a trailing edge. The method also includes printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material, and sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material. The method also includes coupling the erosion shield to the leading edge of the turbine blade.