Ceramic-Reinforced Blisk Insert Flash Sintering for Fiber Integrity
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Solution Overview
Problem
Existing methods for manufacturing bladed turbine wheels with metal matrix composite (MMC) inserts face challenges such as precise temperature and duration control in hot isostatic compaction, risk of damage to ceramic fibers, deformation, and modification of reinforcement positioning, leading to suboptimal compaction and structural integrity issues.
Innovation Solution
The method involves winding ceramic fibers around a mandrel, consolidating with a first metal powder using flash sintering to achieve a 60-80% compaction rate, and then densifying within a mold using a second metal powder through flash sintering, reducing the risk of fiber damage and ensuring high densification efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot isostatic compaction is used to compact and weld the insert, then the part achieves good compaction and welding, but the ceramic fibers may be damaged and the reinforcement positioning may be modified
Solution Approach 1:
The patent changes the compaction parameters by using flash sintering with controlled electric current pulses instead of conventional hot isostatic pressing. This allows achieving high compaction (60-80% during consolidation, >95% after densification) while maintaining fiber integrity through precise control of temperature, time, and pressure parameters during the sintering process
Solution Approach 2:
The compaction process is divided into two distinct stages: consolidation on the mandrel achieving 60-80% compaction, and subsequent densification in the mold achieving >95% compaction. This segmentation allows optimized processing conditions for each stage, preventing fiber damage while achieving high final density
2Manufacturing precision
If hot isostatic compaction is used to ensure good compaction, then the part achieves satisfactory densification, but the cycle time is extended and temperature control must be precise
Solution Approach 1:
The patent uses flash sintering which rapidly heats and densifies the insert in a very short time period. The electric current pulses enable quick heating rates and short holding times, dramatically reducing the cycle time compared to conventional hot isostatic pressing while achieving >95% densification
Solution Approach 2:
The flash sintering process utilizes rapid phase transitions through electric current heating, where the material quickly transitions from a loose, porous state to a dense, sintered state. This phase transition occurs rapidly under controlled electric pulses, achieving high densification without extended processing times
3Ease of manufacture
If the insert is transferred from the winding tool to the mold, then the insert can be positioned for final processing, but the fiber bundle may deform
Solution Approach 1:
The insert is pre-consolidated on the mandrel to achieve 60-80% compaction before transfer to the mold. This preliminary consolidation action strengthens the insert structure, making it more rigid and resistant to deformation during the transfer operation, while still allowing for positioning adjustments
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 allows for rapid, high-density manufacturing with reduced risk of fiber damage and deformation, achieving compaction rates above 95%, enhancing the structural integrity and handling of bladed wheels while minimizing cycle times.
Implementation Method 1
consolidation on the mandrel of the insert by flash sintering with a first metal powder constituting the bladed wheel to be manufactured
Implementation Method 2
densification of the insert by flash sintering with the second metal powder in the mold
Implementation Method 3
carrying out a hot isostatic compaction cycle in order to compact and weld by diffusion all the elements present in the mold
Data Source
Figure 1~2
Figure 3~5a
Figure 5b~6a
AI summary
The invention relates to a method for manufacturing a metallic turbomachine bladed disk (blisk) reinforced with an insert made of a metallic matrix composite material, said method comprising the following step: - (E1): winding ceramic fibres around a mandrel to form the insert, the ceramic fibres being surrounded with a material that makes up the matrix, characterized in that the method comprises the following step: - (E2): flash sintering the insert with a metal powder that forms part of the bladed disk that is to be manufactured.