Composite Turbine Blade Tip Plate Design
Solution Overview
Problem
Turbine blades in gas turbine engines face challenges due to uniform alloy composition, which does not allow for optimal selection of materials for different stress and temperature zones, leading to oxidation and cracking at the tip, reducing efficiency and requiring premature replacement.
Innovation Solution
A composite turbine blade design featuring a first material for the blade portion and a second material for the tip plate, with a hollow interior cavity and an orifice, allowing for varying metallurgical properties to address specific thermal and mechanical stresses, and an insert within the platform to enhance strength, using materials like René and HAYNES alloys for improved creep resistance and oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform alloy composition is used for the entire turbine blade, then the manufacturing process is simplified and the blade structure is uniform, but the blade cannot achieve optimal material properties for different stress and temperature zones, leading to oxidation and cracking at the tip
Solution Approach 1:
The patent applies local quality by using a uniform alloy composition for the main blade body while incorporating a distinct tip plate material at the blade tip. This allows the tip region to have optimized material properties for oxidation and creep resistance, while the main blade maintains manufacturing simplicity. The tip plate is attached to the blade tip to provide localized enhancement where thermal and mechanical stresses are most severe.
Solution Approach 2:
The patent employs composite materials by combining a base alloy (e.g., René 41 or René 80) for the turbine blade with a different alloy composition for the tip plate (e.g., HAYNES 230 or HAYNES 214). This composite construction allows each material to be selected for its optimal properties in the specific zone it occupies, improving overall blade reliability under varying thermal and mechanical conditions.
2Power
If the blade tip is exposed to extreme temperatures and stresses, then the turbine operates at high efficiency, but the blade tip oxidizes and cracks, requiring premature replacement
Solution Approach 1:
The patent applies parameter changes by modifying the material composition parameters at the blade tip through the use of a tip plate with different alloying elements and ratios. This allows the tip region to have enhanced oxidation resistance and creep strength, enabling the turbine to operate at high temperatures and efficiencies while extending the service life of the blade by preventing tip failure.
3Device complexity
If a single alloy is selected for the turbine blade, then the design and manufacturing process is simplified, but the alloy cannot provide optimal performance properties for all locations on the blade
Solution Approach 1:
The patent applies segmentation by dividing the turbine blade into two distinct material zones: the main blade body and the tip plate. This segmentation allows each zone to be optimized with appropriate material properties for its specific functional requirements, while keeping the overall design and manufacturing process relatively simple through modular construction.
Data Source
AI summary
A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.