Blade Disc Stub Geometry for Contaminant-Free Orbital Welding
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Solution Overview
Problem
Existing methods for orbital friction welding of turbomachine blades to rotor disks often result in structural defects and contamination issues due to inadequate stub design, which is not compatible with orbital welding processes.
Innovation Solution
A method for sizing the junction section between blades and stubs in turbomachine bladed disks, where the ratio of maximum to minimum average ray length is less than or equal to 2, ensuring homogeneous material mixing and contaminant ejection, achieved through a process involving ray tracing to optimize the stub dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stub design is used for orbital friction welding, then welding speed and productivity are improved, but structural defects and contamination occur in the welded joint
Solution Approach 1:
The invention changes the geometric parameters of the stub by defining a specific ratio between the maximum and minimum average lengths of rays sweeping the section (ratio ≤ 2). This parameter optimization ensures that the stub geometry is specifically adapted for orbital friction welding, allowing high welding speeds while preventing structural defects and contamination in the welded joint.
2Manufacturing precision
If stub geometry is optimized for homogeneous material mixing, then weld quality is improved, but manufacturing complexity increases due to precise dimensional requirements
Solution Approach 1:
The invention establishes a clear quantitative parameter (the ray length ratio ≤ 2) that defines the optimal stub geometry. This single governing parameter simplifies the design process by providing a straightforward criterion for achieving homogeneous material mixing, rather than requiring complex multi-parameter optimization.
3Reliability
If material consumption in welding zone is increased to ensure complete welding, then weld reliability is improved, but energy consumption and material waste increase
Solution Approach 1:
The optimized stub geometry with ray length ratio ≤ 2 ensures efficient material mixing and complete welding with minimal material consumption. The specific geometric parameters enable the welding process to achieve reliable joints while minimizing the volume of material that needs to be heated and processed, thereby reducing energy consumption.
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 guarantees a robust, contaminant-free weld with improved stiffness and reduced material recirculation, enhancing the structural quality and homogeneity of the weld, thereby minimizing environmental impact and energy consumption in aircraft manufacturing.
Implementation Method 1
orbital friction welding is a welding process in which the parts to be assembled are brought into contact under force and welded by a circular movement generally defined by an eccentric, and accompanied by a uniform tangential speed, so as to generate a friction and homogeneous heating at the level of a weld junction between the two parts
Implementation Method 2
orbital friction welding is a welding process in which the parts to be assembled are brought into contact under force and welded by a circular movement generally defined by an eccentric, and accompanied by a uniform tangential speed
Data Source
AI summary
A method for sizing a junction section by orbital friction welding between a blade and a stub of a bladed disk for a turbomachine. The section is sized such that the ratio of an average ray length extending fully into the section from a point at the periphery of said section and sweeping across said section, where said average ray length is a maximum average length, and an average length of rays extending completely into the section from another point at the periphery of said section and sweeping through said section, where said average length is a minimum average length, is less than or equal to 2.