Integrally Bladed Rotor Friction Welding for Concurrent Blade Joining
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Solution Overview
Problem
Existing methods for welding rotor blades to a rotor disk in integrally bladed rotors are time-consuming and expensive, as each blade is welded separately, necessitating improved manufacturing and repair techniques.
Innovation Solution
A method involving linear friction welding or other processes, where preform rotor blades are concurrently welded to a rotor disk using a system with a rotor disk fixture, rotor blade fixture, and manipulator, allowing for efficient attachment of rotor blades to preform bases on the disk, with optional mechanical joining of collar segments and machining of excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each rotor blade is individually linear friction welded to the rotor disk, then the welding quality and reliability are maintained, but the manufacturing time and cost increase significantly
Solution Approach 1:
The rotor blades are segmented into two groups: a first set of rotor blades welded in a first orientation, and a second set of rotor blades welded in a second orientation. This segmentation allows parallel welding operations to occur simultaneously on different blades, resolving the contradiction by maintaining individual welding quality while significantly reducing total manufacturing time through concurrent processing
Solution Approach 2:
The rotor disk is pre-positioned in a fixture that establishes predetermined welding orientations for multiple blades before welding begins. This preliminary setup enables simultaneous welding operations without compromising weld quality, as each blade is pre-aligned to its correct welding orientation, thereby resolving the contradiction between maintaining welding reliability and improving manufacturing efficiency
2Manufacturing precision
If each rotor blade is individually welded to the rotor disk, then precise welding control is achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
A single fixture is designed to accommodate and position the rotor disk for welding multiple blades in different orientations simultaneously. This universal fixture performs multiple functions: positioning the rotor disk, establishing welding orientations, and supporting concurrent welding operations. This resolves the contradiction by reducing manufacturing complexity through consolidation while maintaining precise welding control through the fixture's built-in positioning features
Solution Approach 2:
Multiple welding operations that would traditionally be performed separately are merged into a single coordinated process using the fixture. The fixture combines positioning, alignment, and support functions for multiple blades, allowing simultaneous welding operations. This merging reduces overall manufacturing complexity while maintaining the precision needed for quality welds on each individual blade
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 method significantly reduces the time and cost of manufacturing and repairing integrally bladed rotors by enabling simultaneous welding of multiple rotor blades, enhancing efficiency and reducing the complexity of the process.
Implementation Method 1
The welding may be or include linear friction welding and/or any other welding process
Implementation Method 2
oscillating the preform rotor blades along a weld plane; and pressing the oscillating preform rotor blades against the stationary rotor disk
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Systems and methods are provided related to manufacturing, repairing or otherwise providing an integrally bladed rotor. In one method, a set of preform rotor blades (28) are arranged relative to a rotor disk (22). The preform rotor blades (28) are concurrently bonded to the rotor disk (22).