Additive Blade Extension with Internal Cooling Channels
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Solution Overview
Problem
Conventional manufacturing methods for airfoil components in turbomachines are inefficient and costly, lacking the ability to effectively extend internal features and optimize component density for improved performance.
Innovation Solution
The development of a rotor blade with an additive portion that includes an internal air chamber with a larger cross-section than the air channels, built using additive manufacturing techniques, which reduces the overall component density and extends internal features from a pre-existing airfoil body to an external surface, enhancing airflow and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used to manufacture airfoil components, then manufacturing precision and structural integrity can be maintained, but manufacturing efficiency is low and cost is high
Solution Approach 1:
The airfoil component is divided into a pre-existing portion (manually manufactured) and an additive portion (additively manufactured), allowing different manufacturing methods to be applied to different sections of the same component. This segmentation enables the additive portion to be manufactured with higher efficiency while the pre-existing portion maintains proven structural integrity
Solution Approach 2:
The patent combines conventional manufacturing and additive manufacturing processes to create a hybrid component. The pre-existing airfoil body serves as a base that is merged with an additive portion, integrating the advantages of both manufacturing methods into a single functional component
2Productivity
If additive manufacturing is used to extend internal features, then manufacturing efficiency and design flexibility improve, but component density decreases
Solution Approach 1:
The additive portion is specifically designed with internal air chambers and extended air channels that are not present in the pre-existing portion. This local modification allows internal features to be extended without requiring the entire component to have reduced density, maintaining structural integrity where needed while adding functionality where required
3Reliability
If the additive portion includes internal air chambers with larger cross-sections, then airflow performance is enhanced, but material usage increases
Solution Approach 1:
The additive portion incorporates internal air chambers that create a porous-like structure with void spaces. These chambers are strategically positioned to enhance airflow paths without requiring solid material to fill the entire volume, thus improving airflow performance while minimizing material usage compared to a fully solid structure
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 allows for the creation of lighter, more efficient airfoil components with optimized internal structures, reducing material usage and enhancing performance by creating a hybrid component with lower density additive structures that extend internal features, thereby improving airflow and structural integrity.
Implementation Method 1
Some additive manufacturing allows a component to be formed from a reserve of fine metal powder positioned on a build plate, which is processed by an electron beam or laser (using fusing heat treatments such as sintering or melting) to form a component or sub-component.
Implementation Method 2
processed by an electron beam or laser (using fusing heat treatments such as sintering or melting) to form a component or sub-component
Data Source
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AI summary
This disclosure provides components and methods for blade 200, 400, 500, 600 extensions with internal features. An airfoil 212, 412, 512, 612 extends from a root connector 212, 412, 512, 612 and includes an airfoil body 220, 420, 520, 620 defining at least one air channel 550, 560, 650, 660 enclosed within the airfoil body 220, 420, 520, 620. The air channel 550, 560, 650, 660 extends to a build surface 122. An additive extension extends from the build surface 122 of the airfoil body 220, 420, 520, 620. The additive extension includes an additive structure 250, 430, 540 extending the air channel 550, 560, 650, 660 from the build surface 122 to an external surface 222, 422 of the additive extension.