Turbine Blade Preform Flat Support for Edge-Safe Polishing
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Solution Overview
Problem
In additive manufacturing of turbomachine blades via selective melting on a powder bed, the presence of removable supports at the leading or trailing edge causes defects and irregularities during manual polishing, affecting the aerodynamics of the blades.
Innovation Solution
Integrating a flat surface at the edge of the blade opposite the manufacturing plate, allowing the removable support to be positioned set back from the edge, enabling controlled polishing without direct contact on the edge, thus reducing defects and simplifying the polishing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If removable supports are positioned at the leading or trailing edge of the blade to hold the blade during manufacture, then the blade can be properly supported during selective melting, but the supports cause defects and irregularities on the edge during manual polishing
Solution Approach 1:
The blade structure is segmented by adding a separate flat surface feature at the edge, distinct from the main blade body. This flat serves as a dedicated support attachment zone, separating the support function from the aerodynamic edge function, thereby preventing support residues from directly affecting edge quality
Solution Approach 2:
The flat surface acts as an intermediary element between the removable support and the blade edge. By positioning the support on this intermediate flat rather than directly on the edge, the harmful effect of support residues is isolated from the critical aerodynamic surface, solving the contradiction between support stability and edge quality
2Ease of manufacture
If manual polishing is performed on the edge to remove support residues, then the supports can be removed, but excessive material removal and defects occur due to operator pressure and movement
Solution Approach 1:
The polishing operation is segmented into two distinct zones: the flat surface where support residues are removed, and the edge where no polishing is needed. This segmentation allows operators to polish the flat without affecting the edge geometry, eliminating the harmful effect of excessive material removal from the aerodynamic surface
Solution Approach 2:
The flat surface serves as an intermediary polishing zone that absorbs the harmful effect of manual polishing operations. By directing polishing efforts onto this intermediate flat rather than the edge, the process achieves support residue removal while preserving edge shape accuracy
3Ease of manufacture
If the removable support is positioned directly on the blade edge, then the blade can be supported during manufacture, but the support residues must be polished from the edge causing time loss and potential defects
Solution Approach 1:
The blade structure is segmented to include a dedicated flat surface at the edge region, separating the support attachment function from the main blade aerodynamic surface. This segmentation enables support residues to be removed from the flat without requiring extensive edge polishing, thereby reducing polishing time
Solution Approach 2:
The flat surface is preliminarily designed and manufactured as part of the blade structure before support attachment. This preliminary action creates a predetermined polishing zone that facilitates rapid support residue removal, reducing the time required for the final polishing operation
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 ensures homogeneous and controlled polishing, reducing the risk of edge defects and shortening the polishing time, while allowing for optional removal of the flat by machining, ensuring adherence to shape specifications.
Implementation Method 1
a step of selective melting of part of the layer of powder deposited using a heating device
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a method for manufacturing, by selective powder-bed fusion, a blade preform for a turbine engine including a blade (2) and at least one detachable holder (6) attached to the blade, the blade being manufactured in layers from a first edge (28) of the blade corresponding to a leading edge or a trailing edge of the blade up to a second edge of the blade corresponding to a trailing edge or a leading edge of the blade, the method including manufacturing the detachable holder and the blade, said detachable holder being intended for attachment to a manufacturing plate (5) and to a portion of a surface (2a) of the blade located near the first edge of the blade opposite said manufacturing plate. The surface (2a) of the blade opposite the manufacturing plate comprises a flat (30) extending from said surface, the flat being on a portion of said surface located beyond the first edge (28) of the blade, the holder being attached to the flat or to both the flat (30) and a portion of said surface (2a) located beyond the first edge (28). The invention also relates to method for manufacturing a blade and a nozzle segment of a turbine engine, and a blade preform.