3D-Printed Composite Compressor Blade Axial Layer Stacking

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Solution Overview

Problem

Contemporary methods for manufacturing compressor blades in gas turbines face challenges in maintaining compressor efficiency while reducing mass, as traditional 3D printing methods result in weak radial strength due to layer stacking along the radial direction, limiting blade size and height.

Innovation Solution

A 3D printing method for composite fiber additive-manufacturing (CFAM) compressor blades where layers are bonded perpendicular to the radial direction, incorporating carbon fiber reinforcement oriented along stress fields, allowing for larger blades with reduced mass and stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional 3D printing method is used to manufacture compressor blade, then mass of the blade is reduced, but radial strength of the blade becomes weak due to layer stacking along radial direction

Engineering Contradiction:

Improvemass of compressor bladeVSAvoidradial strength of compressor blade

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent inverts the conventional layer stacking approach by stacking layers in the axial direction (perpendicular to radial direction) rather than along the radial direction. This inversion allows the blade to achieve reduced mass through additive manufacturing while maintaining strong radial strength, as the layers are bonded perpendicular to the radial direction where stress occurs during rotation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs composite materials with carbon fiber reinforcement embedded in the blade structure. The carbon fiber reinforcement is oriented to align with stress fields, providing enhanced strength in critical areas while maintaining the weight reduction benefits of additive manufacturing. This composite approach resolves the contradiction between mass reduction and strength maintenance.

Inventive Principle:

Principle #40Composite materials

2Stress or pressure

If blade chord length is reduced to manage attachment stress, then attachment stress is managed, but compressor efficiency is compromised

Engineering Contradiction:

Improveattachment stress of compressor bladeVSAvoidcompressor efficiency

Core Design Contradiction:

Stress or pressureVSProductivity

Solution Approach 1:

The use of composite materials with carbon fiber reinforcement allows the blade to maintain larger chord length and height dimensions while managing attachment stress through the high strength-to-weight ratio of the composite structure. The carbon fiber orientation aligns with stress fields, providing targeted strength where needed without compromising compressor efficiency.

Inventive Principle:

Principle #40Composite materials

3Stress or pressure

If blade height is limited to manage attachment stress, then attachment stress is managed, but compressor efficiency is compromised

Engineering Contradiction:

Improveattachment stress of compressor bladeVSAvoidcompressor efficiency

Core Design Contradiction:

Stress or pressureVSProductivity

Solution Approach 1:

The composite material construction with carbon fiber reinforcement enables the blade to achieve greater height dimensions while managing attachment stress through optimized material distribution and fiber orientation. The high strength-to-weight ratio of composites allows taller blades that improve compressor efficiency without exceeding stress limits.

Inventive Principle:

Principle #40Composite materials

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 enables significant weight reduction (approximately 80%) and maintains compressor efficiency by orienting fiber reinforcement in line with operational stress fields, enabling the design of larger blades without chord length or height limitations.

Implementation Method 1

a carbon fiber reinforcement embedded in the plurality of layers of the compressor blade portion and oriented in a direction of stress fields of the compressor blade when in operation

Methodology Applied

Scientific EffectFiber reinforcement: Composite Materials

Implementation Method 2

a 3D printing method of a composite fiber additive-manufacturing (CFAM) compressor blade including fiber reinforced layers according to a stacking direction of the composite compressor blade

Methodology Applied

Scientific EffectAdditive manufacturing (3D printing): 3D Printing

Data Source

PatentUS11326455B23D-printed composite compressor blade having stress-oriented fiber and method of manufacturing the same

Publication Date: 2022.05.10 DOOSAN HEAVY IND & CONSTR CO LTD

AI summary

A compressor blade of a gas turbine includes a compressor blade portion including a plurality of layers; and a carbon fiber reinforcement embedded in the plurality of layers of the compressor blade portion and oriented in a direction of stress fields of the compressor blade when in operation. A method of manufacturing the compressor blade includes preparing a composite material including fiber-reinforced layers; forming a first layer of the composite material to extend in a radial direction of the compressor blade; and stacking a second layer of the composite material on the first layer in an axial direction of the compressor blade. The compressor blade is 3D-printed by forming each composite material layer in a radial direction, which layers are stacked in an axial direction. Fiber reinforcement in the composite compressor blade is oriented in line with the stress fields inherent in the operation of the compressor blade.