Bladed Gas Turbine Rotor Deposited Transition Ring
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Solution Overview
Problem
Current manufacturing methods for bladed gas turbine engine rotors are costly, complex, and prone to leakage, with limitations in using high-temperature materials and achieving structural integrity, particularly when joining blades and hub disks from different alloys.
Innovation Solution
The method involves producing a bladed GTE rotor with a deposited transition ring using additive manufacturing, high velocity cold spray, or laser cladding, which bonds the outer blade ring to a hub disk, allowing for the use of various high-temperature materials and reducing the overall size and weight of the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional machining methods are used to form mating interfaces between shanks and hub disk, then geometric complexity can be achieved, but manufacturing cost and process duration increase significantly
Solution Approach 1:
The transition ring is deposited on the inner circumferential surface of the outer blade ring before the hub disk is attached. This preliminary deposition creates the mating interface geometry in advance, eliminating the need for complex subsequent machining operations to form geometrically complex shapes.
Solution Approach 2:
Traditional mechanical machining processes are replaced with additive manufacturing (deposition) processes. The transition ring is built layer-by-layer using additive manufacturing technology, substituting subtractive machining with additive fabrication to reduce manufacturing complexity and cost.
2Reliability
If traditional machining methods are used to form mating interfaces, then interfaces can be created, but complete sealing between shank-disk interfaces is difficult to achieve
Solution Approach 1:
Traditional mechanical sealing methods are replaced with additive manufacturing. The deposition process creates a transition ring that forms a continuous, hermetic seal between the outer blade ring and hub disk, eliminating leakage paths that are difficult to prevent with mechanical machining alone.
Solution Approach 2:
The transition ring acts as a composite structure bridging two different components (outer blade ring and hub disk). It provides both structural connection and sealing function, combining the benefits of mechanical attachment with hermetic sealing in a single integrated solution.
3Strength
If mating shank-disk interfaces are formed using traditional methods, then connections can be made, but overall size and weight of the rotor increase to achieve comparable structural integrity
Solution Approach 1:
The transition ring merges the outer blade ring and hub disk into a more integrated structure. By depositing material directly onto the inner circumferential surface, it creates a seamless transition zone that strengthens the connection while minimizing the additional material required, thus reducing overall rotor weight compared to traditional mechanical attachment methods.
4Manufacturing precision
If multiple precision machining steps are used to form geometrically complex interfaces, then accurate mating surfaces can be achieved, but manufacturing complexity increases
Solution Approach 1:
The transition ring is deposited in advance to create the final mating interface geometry. This preliminary action establishes the precise geometric shape before assembly, eliminating the need for multiple subsequent precision machining steps to achieve accurate mating surfaces.
Solution Approach 2:
Multiple mechanical machining steps are replaced with a single additive manufacturing process. The deposition technology directly creates complex geometries with high precision, substituting a sequence of machining operations with one additive fabrication step, thereby reducing manufacturing complexity.
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 manufacturing costs and complexity, minimizes leakage, and preserves blade strength by using a radially-graded transition ring composition for improved compatibility and reduced thermal cycles.
Implementation Method 1
The method involves producing a bladed GTE rotor with a deposited transition ring using additive manufacturing
Implementation Method 2
The method involves producing a bladed GTE rotor with a deposited transition ring using additive manufacturing, high velocity cold spray, or laser cladding
Implementation Method 3
The method involves producing a bladed GTE rotor with a deposited transition ring using additive manufacturing, high velocity cold spray, or laser cladding
Implementation Method 4
using a radially-graded transition ring composition for improved compatibility and reduced thermal cycles
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Bladed Gas Turbine Engine (GTE) rotors including deposited transition rings are provided, as are embodiments of methods for manufacturing bladed GTE rotors. In one embodiment, the method includes providing an outer blade ring having an inner circumferential surface defining a central opening, and depositing a deposited transition ring on the inner circumferential surface of the outer blade ring. The outer blade ring can be a full bladed ring or an annular grouping of individually-fabricated bladed pieces. After deposition of the transition ring, a hub disk is inserted into the central opening such that the transition ring extends around an outer circumferential surface of the hub disk. The transition ring is then bonded to the outer circumferential surface of the hub disk utilizing, for example, a hot isostatic pressing technique to join the transition ring and the outer blade ring thereto.