Composite BLISK Manufacturing With Spark Plasma Sintering
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Solution Overview
Problem
Existing methods for manufacturing bladed turbine wheels with metal matrix composite (MMC) inserts face challenges such as damage to ceramic fibers during hot isostatic compaction, deformation, and misalignment of reinforcement, requiring precise temperature and duration control.
Innovation Solution
A method involving spark plasma sintering is used to densify the MMC insert, which includes winding ceramic fibers around a mandrel, followed by spark plasma sintering with a metal powder, and then densifying in a mold, achieving compaction rates of 60-80% and 95-99%, thereby minimizing fiber damage and ensuring precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot isostatic compaction is used to densify the MMC insert, then compaction is achieved, but ceramic fibers are damaged and deformation occurs
Solution Approach 1:
The patent changes the processing parameters from conventional hot isostatic compaction to spark plasma sintering, utilizing electrical discharge heating and pulsed current to achieve densification at lower temperatures and shorter times, thereby preventing fiber damage while maintaining compaction quality
Solution Approach 2:
The patent replaces the mechanical compaction system with an electrical field-based sintering system. Spark plasma sintering uses electrical discharge to generate localized heat and direct current pressure, substituting the conventional mechanical isostatic pressure system with an electro-thermal-mechanical coupling process that better preserves fiber integrity
2Reliability
If precise temperature and duration control is implemented during hot isostatic compaction, then fiber damage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs spark plasma sintering which achieves rapid densification in minutes rather than hours, skipping the prolonged high-temperature exposure of conventional hot isostatic compaction. This rush-through approach achieves fiber integrity without requiring complex long-duration temperature control systems
3Ease of manufacture
If transfer of the insert to the mold is performed, then the insert can be processed, but fiber bundle deformation occurs
Solution Approach 1:
The patent merges the winding and sintering operations into a single integrated process. The insert is sintered directly on the mandrel where it was wound, combining the formative and densification steps. This eliminates the separate transfer operation that causes fiber bundle deformation while maintaining manufacturing feasibility
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
Spark plasma sintering reduces the risk of fiber damage and deformation, allowing for efficient and precise manufacturing of bladed wheels with improved mechanical properties and reduced cycle times.
Implementation Method 1
spark plasma sintering the insert with a powder of metal constituting the bladed wheel to be manufactured
Implementation Method 2
inserts made of metal matrix composite (MMC) material to reinforce bladed turbine wheels made of metal alloy. Such inserts are formed by ceramic fibers which reinforce a metal matrix
Data Source
AI summary
A method for manufacturing a metal bladed wheel of a turbomachine reinforced by an insert made of metal matrix composite material, includes winding the ceramic fibers around a mandrel in order to form the insert, the ceramic fibers being surrounded by a material constituting the matrix; and spark plasma sintering the insert with a powder of metal constituting the bladed wheel to be manufactured.