Orbital Friction Welding of Turbine Blades With Controlled Forging Force
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Solution Overview
Problem
Existing orbital friction welding processes for turbomachine rotor blades suffer from structural defects and lack precise control of welding parameters, leading to potential cracking or deformation at the welded junction.
Innovation Solution
A method involving successive phases of friction and forging with controlled normal forces, where the forging force is greater than the friction force and remains constant, ensuring homogeneous material consumption and stress distribution, with specific force tolerances and durations to optimize the weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If orbital friction welding is performed with conventional parameters, then welding speed is maintained, but structural defects and material health deteriorate
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant force approach to a dynamic force profile that varies through three distinct phases (friction, forging, and consolidation). The normal force is dynamically adjusted: initially high during friction to generate heat, then reduced during forging to control material flow, and finally increased during consolidation to ensure bond strength. This dynamic adaptation resolves the contradiction by optimizing both welding speed and structural integrity at different stages of the process.
Solution Approach 2:
The patent employs periodic action through the cyclic variation of normal force applied during the welding process. The force follows a periodic pattern with three phases: a first period with high force for friction heating, a second period with reduced force for forging, and a third period with increased force for consolidation. This periodic modulation of force allows the process to achieve both high welding speed and reliable structural outcomes by adapting force levels to the specific requirements of each phase.
2Device complexity
If constant normal force is applied during orbital friction welding, then process simplicity is maintained, but welding precision and material distribution deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the welding process into three distinct phases, each with its own normal force characteristics. The first phase (friction) uses high normal force for heat generation, the second phase (forging) uses reduced normal force for controlled material flow, and the third phase (consolidation) uses increased normal force for bond strength. This segmentation of the force application profile enables precise control over material distribution and weld junction quality while maintaining relatively simple process implementation through sequential phase execution.
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
The method enhances weld precision and structural integrity by reducing the risk of defects, achieving a more precise radial height and ensuring homogeneous stress distribution, thereby improving the structural and dimensional quality of the bladed disk.
Implementation Method 1
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
a process for orbital friction welding of a blade to a stub on a turbomachine rotor disk, comprising the following successive phases: friction of the blade against the stub with application of a normal friction force; forging of the blade against the stub with application of a normal forging force
Data Source
AI summary
A process for orbital friction welding of a blade to a stub on a turbomachine rotor disk, comprising the following successive phases: friction of the blade against the stub with application of a force friction normal; forging of the blade against the stub with application of a normal forging force; wherein the normal forging force is greater than the normal friction force and essentially constant throughout the forging phase.