Axial Flow Compressor Blade Metal Injection Molding
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Solution Overview
Problem
The manufacturing of axial flow compressor blade units is hindered by high costs and low productivity due to the complexity of mechanical processes involved in shaping the components, which are difficult to achieve with conventional casting or forging techniques.
Innovation Solution
The implementation of a metal injection molding method to create a powdered metal sintered structure with a relative density of 95% or higher and average grain size within 10 to 100 µm, forming the platform and airfoil sections integrally, significantly reducing the need for mechanical processing and enabling the production of complex shapes directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting or forging techniques are used to manufacture axial flow compressor blade units, then the basic blade component shape can be obtained, but the manufacturing time is long and material yield is low due to the need for extensive mechanical processing
Solution Approach 1:
The patent changes the material state from solid (conventional casting/forging) to powder form, enabling the use of sintering processes that can directly form complex geometries including internal passages and cooling channels, thereby reducing or eliminating the need for subsequent mechanical processing operations
Solution Approach 2:
The patent replaces extensive mechanical machining operations with a sintering process that forms the final or near-final geometry directly. The powder metallurgy process substitutes for traditional mechanical manufacturing steps, achieving complex blade shapes without extensive material removal
2Ease of manufacture
If conventional casting or forging techniques are used to manufacture axial flow compressor blade units, then the basic blade component shape can be obtained, but material yield is low due to the need for extensive mechanical processing
Solution Approach 1:
By changing the material form to powder and using sintering, the process achieves near-net-shape manufacturing where the final part geometry is obtained directly from the molded green compact, minimizing material waste and eliminating the need for extensive machining that would otherwise remove significant material
Solution Approach 2:
The patent performs preliminary forming of the complex blade geometry including internal passages and cooling channels during the green compact formation stage, so that the final sintered part requires minimal or no further machining, thereby maximizing material utilization
3Ease of manufacture
If conventional casting or forging techniques are used to manufacture axial flow compressor blade units, then the blade components can be produced, but the manufacturing cost is high due to extensive mechanical processing
Solution Approach 1:
The patent changes the manufacturing approach from solid-state forming with mechanical machining to powder-based sintering, which eliminates or reduces expensive machining operations and associated tooling, thereby reducing overall manufacturing cost while maintaining or improving part quality
Solution Approach 2:
The patent replaces expensive mechanical machining operations with a sintering process that forms complex geometries directly, eliminating the need for multiple machining steps, specialized tooling, and extensive labor, thereby significantly reducing manufacturing cost
4Ease of manufacture
If conventional casting or forging techniques are used to manufacture axial flow compressor blade units, then the blade components can be produced, but the mechanical characteristics are insufficient compared to the required specifications
Solution Approach 1:
The patent uses metal powder as the starting material, which can be composed of alloy powders with specific compositions optimized for mechanical properties. The sintering process creates a metallurgical bond between particles, producing a material with enhanced mechanical characteristics suitable for high-performance compressor blades
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 results in a cost-effective and high-productivity method for producing axial flow compressor blade units with improved mechanical characteristics, specifically suitable for gas turbine stator vane applications, by minimizing mechanical processing and enhancing material yield.
Implementation Method 1
a sintered body forming step in which the green body is sintered to provide the powdered metal sintered body having a shape corresponding to the shape of the axial flow compressor blade unit
Data Source
Figure 1~2
Figure 3~4
AI summary
An axial flow compressor blade unit (1) including a platform section (2) and an airfoil section (3), which are used as arranged on a circumference about an axis of the compressor. The platform section (2) includes an inner diametric surface segment (2b) inwardly of the circumference, an outer diametric surface segment (2c) outwardly of the circumference, two annular side surface segments (2d) extending in a circumferential direction, two axially side surface segments (2e) extending in the axial direction, and a coupling portion (2a) formed in each of the annular side surface segments (2d) so as to extend in the circumferential direction and being of a shape projecting or recessed in the axial direction. The airfoil section (3) is formed to erect from the platform section (2) so as to extend in a radial direction. The platform section (2) and the airfoil section (3) are formed integrally with each other while having a powdered metal sintered structure.