Dual-Laser Welding of Turbine Vanes With Low Distortion
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Solution Overview
Problem
Conventional welding methods for gas turbine engine components, such as fan outlet guide vanes (OGVs) to core casings, face challenges due to complex aerofoil structures, limited access, curvature issues, and the need for vacuum chambers, leading to uneven welding, distortion, and increased costs.
Innovation Solution
A system utilizing two laser heads, each emitting a laser beam on opposing sides of the components, controlled by a controller to adjust power and movement independently, allowing for precise welding without a vacuum chamber, accommodating complex shapes and maintaining material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single head laser welding or electron beam welding is used, then welding can be performed on OGVs with complex aerofoil structures, but welding accuracy and quality deteriorate due to limited access and curvature
Solution Approach 1:
The welding system is divided into multiple independent laser heads (at least two), each positioned to access different portions of the OGV welding zone. This segmentation allows each laser head to focus on specific areas with favorable access conditions, thereby maintaining high welding precision across the entire complex aerofoil structure while preserving the ability to manufacture welds on difficult-to-reach surfaces
2Strength
If single head laser welding is used to produce deep penetration on thicker leading edges, then welding can be achieved on thick sections, but distortion increases and material thickness becomes non-uniform
Solution Approach 1:
Multiple laser heads are positioned to weld from opposite sides of the OGV simultaneously or sequentially. The welding forces and thermal inputs from opposite directions counterbalance each other, preventing the development of asymmetric stresses that cause distortion. This allows deep penetration welding of thick leading edges while maintaining uniform material thickness and component geometry
3Strength
If electron beam welding is used for welding large structures like full rings of OGVs, then strong weld joints can be produced, but the requirement for large vacuum chambers increases overall cost
Solution Approach 1:
The patent replaces electron beam welding (which requires vacuum chambers) with laser beam welding technology. Laser welding achieves comparable or superior weld joint strength without requiring vacuum conditions, thereby eliminating the need for complex and expensive vacuum chamber systems while maintaining the capability to weld large structures such as full rings of OGVs
4Device complexity
If single head welding is used on opposing sides, then welding process is simpler, but access to opposing side becomes difficult due to unclear line of sight
Solution Approach 1:
The welding system uses multiple laser heads positioned at different locations to access different portions of the welding zone. Each laser head is independently controllable and can be positioned to provide clear line of sight to its target area, eliminating the access problems that arise when a single head must service the entire welding zone including obscured opposing sides
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 system provides accurate and distortion-free welding, reducing costs by eliminating the need for vacuum chambers and improving weld quality across varying cross-sections and thicknesses.
Implementation Method 1
a first laser head configured to emit a first laser beam... a second laser head configured to emit a second laser beam
Data Source
AI summary
A system for welding a first component to a second component. The system includes a first laser head configured to emit a first laser beam and be movably disposable on a first side of the first component. The system further includes a second laser head configured to emit a second laser beam and be movably disposable on an opposing second side of the first component. The system further includes a controller configured to independently control a first power of the first laser beam and a second power of the second laser beam. The controller is also configured to independently and simultaneously control movement of the first laser head and movement of the second laser head relative to the first component.