One-Piece Bladed Disc Sintering for Creep-Strength Balance
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Solution Overview
Problem
The manufacture of turbomachine bladed disks faces challenges such as increased mass due to excessive material dimensioning, premature wear from friction, and the need for compromise between creep and tensile resistance, as well as limitations in geometry and material adaptation for specific stresses, particularly in integrally formed blisks.
Innovation Solution
A method involving spark plasma sintering of blades with metal powders to form an integrally formed bladed disk, where the root is embedded in one metal powder and the profiled portion protrudes, allowing for the use of monocrystalline blades and a polycrystalline central hub with varying mechanical properties, and optionally using multiple metal powders for the central hub to optimize creep and tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the central hub is dimensioned by increasing the amount of material to avoid faults during machining, then the reliability of the bladed disk is improved, but the mass of the disk increases
Solution Approach 1:
The invention applies preliminary action by embedding the blade roots into the central hub material before the final machining operation. The blade roots are positioned and fixed in advance, allowing the central hub to be machined to exact dimensions without requiring excessive material reserves, thereby reducing mass while maintaining reliability
Solution Approach 2:
The invention merges the blade roots with the central hub material through embedding, creating an integrated structure where the blade roots become part of the hub matrix. This combination eliminates the need for separate mounting operations and allows optimized material distribution, reducing overall mass while ensuring structural integrity
2Ease of manufacture
If the blade root geometry is constrained to allow insertion into cells, then the ease of manufacture is improved, but the adaptability of blade geometry is limited
Solution Approach 1:
The blade roots are embedded into the central hub material before the final machining of the hub. This preliminary positioning allows the blade roots to have complex, optimized geometries without constraining the subsequent machining operations, as the embedding process accommodates various root shapes while the hub is machined to precise dimensions
Solution Approach 2:
The invention changes the manufacturing parameters by using an embedding process rather than traditional insertion into pre-machined cells. This allows the blade root geometry parameters to be optimized for performance without being constrained by the need to fit into standardized cell geometries, enabling greater design flexibility
3Strength
If machining is performed in the mass of a forged raw material, then the strength of the bladed disk is improved, but the choice of vane material is constrained by the disk material
Solution Approach 1:
The invention segments the bladed disk into two distinct material components: the central hub made from forged material providing overall strength, and the blades made from separate material powders embedded in the hub. This segmentation allows each component to be optimized with different materials suited to their specific functional requirements, with the hub providing structural strength and the blades providing aerodynamic performance
Solution Approach 2:
The invention uses composite materials by combining forged hub material with embedded blade material powders. The hub is made from a base material providing structural integrity, while the blades are formed from different material compositions optimized for their specific stresses, creating a multi-material composite structure with superior overall performance
4Adaptability or versatility
If the disk and vanes are assembled, then the adaptability of materials for specific stresses is improved, but the assembled area requires over-dimensioning to meet thermomechanical stresses
Solution Approach 1:
The invention merges the blade roots with the central hub material through the embedding process, creating an integrated structure where the interface between hub and blades is eliminated. This eliminates the need for over-dimensioning the assembly area to compensate for potential interface failures, as the embedded roots become part of the hub matrix, allowing precise dimensional tolerances and reducing overall mass
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 reduces wear, allows for better geometry and material adaptation, and avoids destabilization of metallurgical structures, resulting in a bladed disk with improved resistance to creep and traction while maintaining the benefits of integrally formed designs.
Implementation Method 1
spark plasma sintering the blades with a metal powder, the blades being angularly distributed over a contour of an annular spark plasma sintering mold
Data Source
AI summary
A method for manufacturing an integrally formed bladed disk of a turbomachine, includes manufacturing a plurality of blades, the blades including a root and a profiled portion; and spark plasma sintering the blades with a metal powder, the blades being angularly distributed over a contour of an annular spark plasma sintering mold, the root of the blades being embedded into the metal powder, the profiled portion of the blades protruding from the metal powder radially outwardly.