Turbine Blade Tip Cladding With Shrouds for Near-Net Shape
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Solution Overview
Problem
Manufacturing turbine rotor blade tips to withstand thermal loading is time-consuming and costly, requiring complex processing to achieve the desired dimensional form.
Innovation Solution
The method involves installing a turbine blade in a fixture with shroud components positioned to contain and define the cladding, using laser tip cladding to apply a high-temperature-resistant material, where the shroud components ensure a near-net shape with minimal post-processing needed, and applying a protective platinum aluminide layer for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing operations are used to process the covered blade tip into final dimensional form, then the blade tip can withstand thermal loading, but the manufacturing process becomes time consuming and costly
Solution Approach 1:
The shroud components are positioned and secured to the blade tip before cladding application, pre-defining the final dimensional boundaries. This preliminary action ensures that the cladding is deposited precisely to the required profile, eliminating the need for subsequent material removal operations and significantly reducing post-cladding machining time
Solution Approach 2:
The shroud components act as intermediary tools that temporarily constrain the cladding material during deposition. These shrouds define the exact boundaries of the cladding layer, serving as a physical mediator between the cladding process and the final dimensional requirements, thereby eliminating complex post-processing operations
2Manufacturing precision
If traditional manufacturing operations are used to process the covered blade tip into final dimensional form, then the desired profile can be achieved, but the process becomes exceedingly challenging
Solution Approach 1:
The shroud components serve as intermediary constraint tools that physically define the boundaries of the cladding deposition. By positioning the shrouds against the blade tip before cladding, the exact dimensional profile is pre-established, allowing the cladding process to achieve high precision without requiring complex post-processing machinery or operations
Solution Approach 2:
The shrouds are installed and secured to the blade tip in advance of cladding application, pre-defining the final dimensional boundaries. This preliminary constraint setup ensures that the cladding material is deposited precisely within the required profile from the outset, eliminating the need for complex material removal operations
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 significantly reduces the need for post-cladding machining, enhances the durability of the blade tips, and improves manufacturing efficiency by achieving the desired profile with minimal material removal, allowing for direct assembly into engines with reduced processing costs.
Implementation Method 1
laser tip cladding to apply a high-temperature-resistant material
Implementation Method 2
The protective material layers are fused to the blade as a result of applying the cladding
Data Source
AI summary
Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.