Casting Method for Gas Turbine Components
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Solution Overview
Problem
Hard-to-weld alloys, such as nickel-based superalloys and certain aluminum-titanium alloys, are difficult to repair due to gamma prime strain aging, liquation, and hot cracking, leading to increased costs and waste as damaged components are often discarded rather than repaired.
Innovation Solution
A casting method that integrates two compositionally distinct materials with different grain structures into a single, continuous article, where one material is subjected to a specific condition to grow a first grain structure, and the other is intermixed with it to form a hybridized region with a distinct second grain structure, enhancing the mechanical properties and weldability of the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If HTW materials are used to form gas turbine components, then operational properties are improved, but reparability deteriorates due to difficulty in joining and repairing
Solution Approach 1:
The patent applies local quality by creating distinct regions within the component with different material compositions and grain structures. The first region contains HTW material with gamma prime phase for superior operational properties in extreme conditions, while the second region has modified composition with reduced gamma prime for improved reparability. This spatial differentiation allows the component to have both high reliability in critical areas and ease of repair in other areas.
Solution Approach 2:
The patent employs composite materials by integrating two compositionally distinct materials into a single continuous component. The first material is a HTW alloy with gamma prime phase, and the second material has a composition that reduces gamma prime content. This composite structure combines the advantages of both materials, achieving superior operational properties where needed while maintaining reparability in other regions.
2Reliability
If HTW materials with high gamma prime content are used, then operational performance is improved, but weldability and joining difficulty increase
Solution Approach 1:
The patent applies local quality by creating distinct regions within the component with different material compositions and grain structures. The first region contains HTW material with gamma prime phase for superior operational properties in extreme conditions, while the second region has modified composition with reduced gamma prime for improved reparability. This spatial differentiation allows the component to have both high reliability in critical areas and ease of repair in other areas.
Solution Approach 2:
The patent employs composite materials by integrating two compositionally distinct materials into a single continuous component. The first material is a HTW alloy with gamma prime phase, and the second material has a composition that reduces gamma prime content. This composite structure combines the advantages of both materials, achieving superior operational properties where needed while maintaining reparability in other regions.
3Ease of repair
If standard repair techniques are applied to HTW components, then repair attempts are made, but the deposited material is weakened or cracked by elevated temperatures
Solution Approach 1:
The patent applies local quality by creating distinct regions within the component with different material compositions and grain structures. The first region contains HTW material with gamma prime phase for superior operational properties in extreme conditions, while the second region has modified composition with reduced gamma prime for improved reparability. This spatial differentiation allows the component to have both high reliability in critical areas and ease of repair in other areas.
Solution Approach 2:
The patent uses an intermediary approach by incorporating a second material with reduced gamma prime content that serves as a more repair-friendly region. This intermediary material acts as a bridge between the high-performance HTW material and standard repair techniques, allowing repairs to be performed without the severe limitations imposed by the gamma prime phase while maintaining overall component integrity.
4Reliability
If HTW materials are used, then component performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating distinct regions within the component with different material compositions and grain structures. The first region contains HTW material with gamma prime phase for superior operational properties in extreme conditions, while the second region has modified composition with reduced gamma prime for improved reparability. This spatial differentiation allows the component to have both high reliability in critical areas and high reliability in other areas.
Solution Approach 2:
The patent employs composite materials by integrating two compositionally distinct materials into a single continuous component. The first material is a HTW alloy with gamma prime phase, and the second material has a composition that reduces gamma prime content. This composite structure combines the advantages of both materials, achieving superior operational properties where needed while maintaining reparability in other regions.
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 decreases costs, increases reparability, and improves the mechanical properties and elevated temperature performance of gas turbine components, reducing waste and extending service intervals.
Implementation Method 1
The first material is subjected to a first condition suitable for growing a first grain structure. The first grain structure is grown from a first portion of the first material, forming the first region of the article while maintaining a second portion of the first material in the molten state.
Implementation Method 2
A second portion of the second material is subjected to a second condition suitable for growing a second grain structure. The second grain structure is distinct from the first grain structure. The second grain structure is grown from the second portion of the second material, forming the second region of the article.
Implementation Method 3
A hybridized material is formed by intermixing a first portion of the second material with the second portion of the first material.
Data Source
Figure 1
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AI summary
Casting methods and articles (100) are disclosed wherein a molten first material (108) is introduced into a mold (200) which distributes the first material (108) to form a first region (102) of the article (100) where it is subjected to a first condition suitable for growing a first grain structure, forming the first region (102) of the article (100). A molten second material (110), compositionally distinct from the first material (108), is introduced into the mold (200) to form a second region (104) of the article (100). A hybridized material (112) is formed by intermixing a first portion (500) of the second material (110) with the second portion (302) of the first material (108). A second portion (502) of the second material (110) is subjected to a second condition suitable for growing a second grain structure distinct from the first grain structure, forming the second region (104) of the article (100). The first region (102) and the second region (104) are integrally formed as a single, continuous article (100) with a hybridized region (106) formed between.