Gas Turbine Burner Component 3D Printing Speed Optimization
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Solution Overview
Problem
3D additive manufacturing for gas turbine combustor burner components faces challenges in optimizing material strength per part while minimizing production time and cost, as increasing laser scanning speed reduces material density and strength, necessitating a balanced approach to lamination speeds for varying temperature and stress regions.
Innovation Solution
A method involving 3D additive manufacturing that differentiates lamination speeds for burner components based on temperature and stress ranges, applying lower speeds for high-temperature/high-stress areas and higher speeds for low-temperature/low-stress areas to optimize material strength and reduce production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser scanning speed is increased to reduce lamination time, then productivity is improved, but relative density of material is reduced
Solution Approach 1:
The patent applies different lamination speeds to different regions of the burner component based on their functional requirements. High-temperature regions use lower lamination speeds to ensure high relative density and material strength, while low-temperature regions use higher lamination speeds to reduce production time. This local differentiation resolves the contradiction between productivity and manufacturing precision by optimizing each region's lamination parameters according to its specific demands.
2Strength
If lamination speed is reduced to increase relative density, then material strength is improved, but time taken for lamination is increased
Solution Approach 1:
The patent implements region-specific lamination speed control where only critical high-temperature regions undergo slow lamination to achieve high material strength, while non-critical low-temperature regions are rapidly laminated. This selective approach maintains necessary strength requirements in essential areas while minimizing overall lamination time, thus resolving the contradiction between material strength and lamination time.
Solution Approach 2:
The burner component is segmented into multiple temperature zones (high-temperature regions and low-temperature regions), and each segment is processed with appropriate lamination speed. This segmentation allows the system to apply stringent quality control only where necessary, rather than uniformly across the entire component, thereby reducing total production time while maintaining required strength in critical areas.
3Ease of manufacture
If uniform lamination speed is applied to entire burner, then manufacturing process is simplified, but material strength cannot be optimized per part
Solution Approach 1:
The patent employs automated control systems that adjust lamination speed based on pre-defined temperature zone mappings of the burner component. This approach maintains relative process simplicity through automation while achieving local optimization of material strength. The system automatically identifies high-temperature regions and applies appropriate lamination parameters, eliminating the need for manual intervention while still achieving part-specific strength optimization.
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 the optimization of material strength per part, enhancing environmental performance and cost efficiency in gas turbine combustor manufacturing by optimizing material properties and reducing production time.
Implementation Method 1
it becomes possible to manufacture a complicated structure by irradiating metal powders with laser and thereby sintering the metal powders
Data Source
AI summary
There is provided a gas turbine combustor which includes a burner component which is molded by 3D additive manufacturing and is optimized in material strength per part. The burner component includes a first part which is used within a first temperature range and/or a first stress range and a second part which is used within a second temperature range which is lower than the first temperature range and/or a second stress range which is lower than the first stress range, and a lamination speed at which a metal material is laminated on the first part by the 3D additive manufacturing is lower than a lamination speed at which the metal material is laminated on the second part.