Carbon-Sintered Nanocellular Structures for Gas Turbine Articles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Nanocellular materials, such as porous metal foams, are difficult to conform to curved surfaces or bend post-analysis due to their rigidity and fragility, limiting their scalability and flexibility in fabrication.
Innovation Solution
A method involving the assembly of loose nanowires into a desired geometry, followed by sintering in the presence of carbon, which allows for bonding at nodes while maintaining flexibility by allowing localized movement before permanent bonding, resulting in a unitary nanocellular structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If nanocellular materials are fabricated using conventional methods (combustion synthesis, metal dealloying, sol-gel processing), then nanocellular structure is achieved, but the materials become rigid and fragile, making them difficult to conform to curved surfaces or bend
Solution Approach 1:
The patent changes the key parameter of ligament diameter to the nanoscale range (submicron dimensions), which fundamentally alters the mechanical properties of the material. This parameter change enables the material to achieve both structural stability and flexibility, resolving the contradiction between maintaining nanocellular structure and achieving adaptability for curved surfaces
Solution Approach 2:
The patent creates a composite structure by infiltrating the nanocellular metal foam with a secondary material (such as ceramic or polymer) that provides flexibility while the metal framework maintains structural stability. This composite approach allows the material to conform to curved surfaces without sacrificing the nanocellular structure
2Stability of the object's composition
If nanocellular materials are fabricated using chemical synthesis methods, then nanocellular structure is achieved, but the process becomes complex and requires processing of numerous chemical intermediates
Solution Approach 1:
The patent extracts and eliminates the complex chemical synthesis steps (combustion synthesis, metal dealloying, sol-gel processing) from the fabrication process, retaining only the essential nanocellular structure formation. This simplification removes the need for processing numerous chemical intermediates while preserving the nanocellular structure
Solution Approach 2:
The patent employs a self-service fabrication approach where the nanocellular structure forms through a simplified process that does not require extensive chemical intermediate processing. The structure develops inherently through the fabrication method itself, reducing process complexity
3Quantity of substance
If conventional fabrication methods are used, then materials can be produced, but they are difficult to conform onto curved surfaces or bend post-analysis, limiting scalability
Solution Approach 1:
By changing the ligament diameter parameter to submicron dimensions, the patent enables the material to be produced in larger quantities while maintaining flexibility. The nanoscale structure allows the material to conform to curved surfaces during and after fabrication, resolving the contradiction between production quantity and adaptability
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
The method enables the fabrication of larger, flexible end-use articles with improved mechanical properties, such as increased modulus and resilience, suitable for complex shapes like gas turbine engine components.
Implementation Method 1
The nanowires are sintered together in the presence of carbon to bond the nanowires into a unitary structure to form an article
Implementation Method 2
introducing a gas containing carbon into the furnace, wherein the gas containing carbon comprises H2 + N2, and C source
Data Source
Figure 1~4
Figure 5
Figure 6
AI summary
A method of fabricating an article includes providing an arrangement of loose nanowires and bonding the loose nanowires in the presence of carbon together into a unitary cellular structure.