Near-Net Shape Erosion Shield via Laser Deposition

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for manufacturing erosion shields for turbine components, such as build-up welding and machining of cobalt chromium alloys, are time-consuming and costly, especially for complex shapes like turbine blades, and do not efficiently address erosion caused by water droplets and fine dust in steam turbines.

Innovation Solution

A method using laser-aided manufacturing (LAM) to deposit wear-resistant materials directly onto a base, forming a near-net shape erosion shield that can be easily secured to turbine components, reducing the need for extensive machining and processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If build-up welding is used to create erosion protection, then erosion resistance is improved, but manufacturing time and processing complexity increase significantly

Engineering Contradiction:

Improveerosion resistanceVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical build-up welding processes with a thermal field-based deposition process. The energy beam (laser, electron beam, or plasma) provides localized heating to melt and deposit wear-resistant material directly onto the turbine component, eliminating the need for complex multi-step welding operations and subsequent machining.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent performs preliminary shaping of the wear-resistant layer during the deposition process itself. By controlling the energy beam parameters and deposition conditions, the material is deposited in near-net shape that closely matches the final desired geometry, eliminating or minimizing the need for post-deposition machining operations.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional build-up techniques are used, then erosion protection is achieved, but the erosion portion requires extensive machining after formation

Engineering Contradiction:

Improveerosion protectionVSAvoidprocessing steps

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical machining operations with a thermal field-based deposition process. The energy beam directly deposits material in the desired shape, eliminating the need for subsequent mechanical machining to achieve the correct geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

3Reliability

If wrought cobalt chromium alloy shields are used, then wear resistance is improved, but manufacturing cost and processing complexity increase for complex shapes

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical machining of wrought alloy shields with a thermal field-based deposition process. The energy beam directly deposits wear-resistant material in the desired complex geometry, eliminating the need for expensive and time-consuming machining operations required for traditional wrought alloy shields.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing parameters from mechanical processing of pre-formed wrought alloys to thermal deposition of material in-situ. This allows direct formation of complex geometries without the need for expensive machining operations, significantly reducing manufacturing cost for complex turbine component shapes.

Inventive Principle:

Principle #35Parameter changes

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 significantly decreases manufacturing time and costs, increases efficiency, and allows for complex geometries and alloy blending, effectively protecting turbine components from erosion while minimizing processing steps.

Implementation Method 1

depositing at least one wear resistant material over the base with an energy beam from the energy source

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

depositing at least one wear resistant material over the base with an energy beam from the energy source

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS9695697B2Erosion shield, method of fabricating a shield, and method of fabricating an article having a shield

Publication Date: 2017.07.04 GE INFRASTRUCTURE TECH LLC

AI summary

A method of fabricating a near-net shape erosion shield, a method of forming a shielded article, and a near-net shape erosion shield are provided. The method of fabricating a near-net shape erosion shield includes providing a base, positioning an energy source relative to the base, and depositing at least one wear resistant material over the base with an energy beam from the energy source. The at least one wear resistant material deposited on the base forms the near-net shape erosion shield configured to be positioned on a turbine component. The method of forming a shielded article includes removing the base from the near-net shape erosion shield, and securing the near-net shape erosion shield to a turbine component. The near-net shape erosion shield includes a near-net shape erosion-resistant portion configured to be positioned on a turbine component.