Turbine Blade Tip Laser Cladding With Shroud-Defined Net Shape
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Solution Overview
Problem
Manufacturing turbine blade tips to withstand thermal loading in gas turbine engines is time-consuming and costly, and existing methods require extensive post-processing to achieve the desired shape and durability.
Innovation Solution
The method involves laser cladding with shroud components acting as containment tools to form a parapet wall on the blade tip, using a selected material for its toughness and heat resistance, which defines a near-net shape requiring minimal to no post-cladding machining, and applying a protective platinum aluminide layer for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to process blade tips, then the blade tips can withstand thermal loading, but the manufacturing process is time-consuming and costly with extensive post-processing required
Solution Approach 1:
The patent changes the manufacturing parameters by using laser cladding technology with specific process controls to achieve net-shape fabrication. The laser parameters, material composition, and processing conditions are optimized to produce blade tips with required thermal resistance properties directly during manufacturing, eliminating the need for time-consuming post-processing while maintaining reliability
Solution Approach 2:
The patent replaces traditional mechanical machining and post-processing operations with laser-based additive manufacturing. The laser cladding process directly builds the blade tip structure with precise dimensional control, substituting multiple mechanical manufacturing steps with a single automated thermal process that achieves the final shape without extensive post-processing
2Reliability
If traditional manufacturing methods are used to process blade tips, then the blade tips can withstand thermal loading, but extensive post-processing is required to achieve desired shape
Solution Approach 1:
The patent replaces traditional mechanical machining with laser-based additive manufacturing that directly produces the final dimensional form. The laser cladding process incorporates real-time monitoring and control systems that ensure dimensional accuracy is achieved during the building process itself, eliminating the need for post-processing operations while maintaining manufacturing precision
Solution Approach 2:
The manufacturing process is designed to be self-correcting and self-finishing through automated laser control systems that monitor and adjust parameters in real-time. The process inherently produces net-shape components with proper dimensional tolerances without requiring external post-processing interventions, making the system self-sufficient in achieving both thermal resistance and dimensional accuracy
3Ease of manufacture
If laser cladding is used without containment tools, then the process is simpler, but material excess is generated requiring post-cladding machining
Solution Approach 1:
The patent introduces shroud components as intermediary containment tools during the laser cladding process. These shrouds act as temporary formers that confine the molten material precisely where needed, preventing material excess while maintaining process simplicity. The shrouds are easily installed and removed, and the containment they provide ensures net-shape fabrication without complex process modifications
Solution Approach 2:
The patent uses shroud components that function as flexible containment shells during the cladding process. These thin-walled structures conform to the blade tip geometry and provide precise material confinement without adding significant complexity to the manufacturing process. The shrouds are designed for easy installation and removal, maintaining process simplicity while eliminating material excess through precise containment
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 improves manufacturing efficiency by eliminating the need for extensive post-processing, ensuring the blade tip meets specifications with reduced material excess and enhances durability against thermal and erosive conditions.
Implementation Method 1
laser cladding the deposited filler material
Implementation Method 2
laser cladding with shroud components acting as containment tools to form a parapet wall on the blade tip
Implementation Method 3
shroud components acting as containment tools to form a parapet wall on the blade tip
Implementation Method 4
A release agent layer is applied to the shroud component prior to locating the shroud component against the blade
Implementation Method 5
The shrouds may be heated to reduce the incidence of defects
Data Source
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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.