Dual-Walled Turbine Components With AM Cooling and Diffusion Bonding
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Solution Overview
Problem
Existing methods for manufacturing dual-walled components of gas turbine engines are costly, time-consuming, and require complex template-based manufacturing processes, limiting their scalability and efficiency.
Innovation Solution
A method involving separate casting of a single crystal or directionally solidified metal alloy spar and a polycrystalline metal alloy coversheet, with the latter formed via additive manufacturing to include complex cooling features, followed by diffusion bonding to create a dual-walled structure that avoids complex template-based manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex cooling patterns are formed using traditional casting with wax dies and ceramic cores, then the component achieves the necessary cooling functionality, but the manufacturing process becomes extremely expensive and time-consuming with low yield
Solution Approach 1:
The patent replaces traditional mechanical template-based manufacturing (wax dies, ceramic cores) with additive manufacturing technology. This substitution eliminates the need for complex tooling and manual assembly of cooling channels, directly forming the cooling pattern as an integral part of the component structure. The additive manufacturing process enables complex geometries to be created through digital models rather than physical molds, dramatically reducing lead time and manufacturing cost.
Solution Approach 2:
The patent merges the cooling channel formation with the main component manufacturing process. Instead of separately creating cooling channels using wax dies and ceramic cores, the additive manufacturing process forms both the structural component and the cooling pattern simultaneously in a single integrated process. This consolidation eliminates multiple manufacturing steps and reduces overall complexity.
2Strength
If single crystal or directionally solidified alloys are used for the spar to enhance mechanical properties, then strength and creep resistance improve, but manufacturing complexity and cost increase due to specialized casting requirements
Solution Approach 1:
The patent replaces complex directional solidification casting processes with additive manufacturing for forming the spar. This substitution maintains the ability to produce single crystal or directionally solidified microstructures while eliminating the need for specialized casting equipment and complex process control. The additive manufacturing process can precisely control cooling rates and thermal gradients to achieve the desired microstructure without requiring traditional directional solidification apparatus.
3Adaptability or versatility
If separate casting of coversheet and spar is performed, then manufacturing flexibility improves, but the overall process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the manufacturing of the coversheet and spar into a single additive manufacturing process. The cooling pattern is formed as an integral part of the coversheet structure during the same build process that creates the spar, eliminating the need for separate casting operations and subsequent assembly. This integration maintains design flexibility while dramatically reducing total manufacturing time.
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
Enables the fabrication of robust dual-walled components with enhanced mechanical properties and efficient cooling, reducing manufacturing costs and lead times while maintaining structural integrity and temperature resistance.
Implementation Method 1
a primary load carrying structural component (referred to herein as a 'spar') is formed from a substantially single crystal or directionally solidified (DS) metal alloy
Implementation Method 2
a primary load carrying structural component (referred to herein as a 'spar') is formed from a substantially single crystal or directionally solidified (DS) metal alloy
Implementation Method 3
a hot section part (coversheet) is formed from a polycrystalline metal alloy... including a plurality of support structures forming a plurality of cooling channels
Implementation Method 4
The outer surface of the cold section part and the inner surface of the plurality of support structures are diffusion bonded
Data Source
AI summary
A dual-walled component of a gas turbine engine includes a cold section part, such as a spar, and a hot section part, such as a coversheet. The cold section part includes a single crystal or directionally solidified metal alloy and defines an outer surface, a hot section part comprising a polycrystalline metal alloy formed using additive manufacturing. The hot section part includes a plurality of support structures forming a plurality of cooling channels and defining an inner surface. The outer surface of the cold section part and the inner surface of the plurality of support structures are diffusion bonded.