Metal Part Manufacturing via Fibrous Preform Winding and HIP
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and complexity of manufacturing metal reinforcements for large-sized turbine engine fan blades due to their complex geometry, which requires numerous and lengthy forming and machining operations, necessitates a more efficient and cost-effective method.
Innovation Solution
A method involving the creation of a fibrous structure by three-dimensional weaving of metallic wires, followed by hot isostatic pressing, where the fibrous structure is formed by winding metallic wires around an elongate tooling fixture element, allowing for partial automation and incorporation of composite wires with ceramic fibers, enabling the production of parts with varying thickness and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional hot shaping and machining of titanium alloy blanks is used to manufacture reinforcements, then the part achieves the required strength and complex geometry, but the manufacturing cost becomes high and the process becomes lengthy
Solution Approach 1:
The invention changes the material state from solid blank to fibrous structure, and changes the forming method from mechanical shaping to hot isostatic pressing. The fibrous structure is compacted at elevated temperature and pressure to achieve both complex geometry and high strength, while significantly reducing manufacturing steps and cost
Solution Approach 2:
The invention uses composite fibrous structures made of metallic wires (titanium alloy, Inconel) that are woven or wound into three-dimensional patterns. These fibrous composites are then densified through hot isostatic pressing to achieve the required mechanical strength, replacing traditional monolithic titanium alloy blanks
2Shape
If traditional hot shaping and machining operations are used to create complex geometry, then the required shape is achieved, but the number of operations increases and manufacturing time becomes lengthy
Solution Approach 1:
The fibrous structure is pre-formed into the desired complex geometry through three-dimensional weaving or winding before the hot isostatic pressing operation. This preliminary shaping eliminates the need for subsequent machining operations, as the complex geometry is already established in the green state
Solution Approach 2:
The invention merges multiple operations (shaping, forming, and densification) into a single hot isostatic pressing operation. The fibrous structure is compacted and diffusion-bonded in one step, achieving both the required geometry and density without sequential machining steps
3Reliability
If fibrous structure is compacted by hot isostatic pressing, then porosity is reduced to zero or very low levels, but the manufacturing process becomes more complex
Solution Approach 1:
The invention uses hot isostatic pressing with specific parameters (temperature, pressure, time) to transform the fibrous structure into a dense solid part. The controlled application of heat and pressure enables complete densification and diffusion bonding, achieving zero or very low porosity while maintaining process control
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 method reduces manufacturing costs and complexity by producing parts with zero or low porosity and complex geometries, such as turbine engine fan blade reinforcements, through automated winding and hot isostatic pressing, resulting in a cost-effective and efficient production process.
Implementation Method 1
The hot isostatic pressing (HIP) step allows, through compaction, the fibrous structure to be given its final shape and be densified by diffusion bonding together of the metallic wires and/or coatings
Data Source
AI summary
A method for manufacturing a metal part by producing a preform with a fibrous structure of metal fibers, and subjecting the preform to hot isostatic pressing in a tool until a solid part is obtained, the tool including at least one first element including a cavity for molding the part. The first tool element is elongate in a direction between two ends, and the fibrous structure is at least partially formed by winding at least one metal wire around the first tool element in the direction, from one end to the other. The method can be used, for example, for manufacturing reinforcement parts for a fan blade of a turbojet engine.