Compressor Vane Groove Design for Crack-Free Welding
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Solution Overview
Problem
Typical welding techniques and vane designs in compressor assemblies often result in cracks within the welds and airfoils, compromising the integrity of the vane assembly and turbine engines.
Innovation Solution
A vane assembly design featuring inner and outer grooves in the sidewalls of adjacent vanes, allowing for full penetration welding along the joint, which secures the vanes together and reduces cracking by forming channels through the radial thickness of the shrouds, using techniques like TIG or electron beam welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If typical welding techniques are used to join vane assemblies, then the vanes can be connected together, but cracks permeate through the welds and airfoils compromising integrity
Solution Approach 1:
The method performs preliminary actions by preparing precise groove geometries (V-grooves, U-grooves, or combination grooves) in the shrouds before welding. These pre-prepared grooves guide the weld deposition process to achieve full penetration and proper fusion, preventing crack formation during and after welding. The grooves are machined to specific dimensions and angles to ensure optimal weld joint geometry
Solution Approach 2:
The invention changes critical welding parameters including groove geometry (V-shaped, U-shaped, or combination), groove dimensions (depth, width, angle), and welding process parameters (heat input, welding speed, electrode positioning). By optimizing these parameters, the weld achieves full penetration through the shroud thickness while maintaining crack-free joints and proper microstructure
2Reliability
If full penetration welding is achieved through grooves in inner and outer sidewalls, then crack prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The welding joint is segmented into distinct components: the groove geometry (V-groove, U-groove, or combination), the weld metal deposition zones, and the fusion zones. This segmentation allows each component to be optimized independently for crack prevention while simplifying the overall manufacturing process through standardized groove configurations that can be replicated across multiple vane assemblies
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
The solution effectively prevents cracking in the welds of the vane assembly, enhancing the structural integrity and reliability of compressor components, particularly in high-speed rotating applications.
Implementation Method 1
A first vane assembly is then secured to a second vane assembly by a welding process to form a welded vane assembly
Implementation Method 2
using techniques like TIG or electron beam welding
Data Source
AI summary
Aspects of the present invention relate to systems and methods of a vane design utilizing welding techniques. The present invention concerns a method for preventing cracking within a vane assembly utilizing full penetration welding. Additional embodiments concern a vane design that, when assembled with another vane, comprises an axial slot that prevents cracking within a vane assembly.