Friction Welding Gas Turbine Blade Stalks
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Solution Overview
Problem
Existing methods for coupling gas turbine engine blades with disks and repairing them are inefficient, lacking in robustness and precision, particularly in applications requiring high reliability and durability.
Innovation Solution
The apparatus and method involve a gas turbine engine component with a blade and a platform forming an airflow surface, a motion weld receiving surface on the non-airflow side, and a disk with a corresponding motion weld disk portion, utilizing friction welding by imparting loads and creating relative movement between the blade and disk to form a strong coupling, and allowing for the removal and replacement of blades using techniques like wire electro-discharge machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction welding is used to couple blades with disks, then the strength and reliability of the coupling is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The blade and disk surfaces are pre-prepared with specific geometric features (motion weld receiving surface and motion weld disk portion) before the friction welding process. This preliminary preparation ensures proper alignment and contact during welding, improving coupling reliability while maintaining process efficiency by avoiding complex real-time adjustments during the welding operation itself.
2Duration of action of stationary object
If traditional coupling methods are used, then the manufacturing process is simpler, but the durability and precision of the blade-disk coupling deteriorates
Solution Approach 1:
The invention changes the physical and geometric parameters of the coupling interface by creating specific motion weld surfaces with controlled geometry, surface finish, and material properties. This parameter optimization enables durable couplings that withstand operational stresses while maintaining a relatively simple manufacturing process through standardized preparation procedures.
3Ease of repair
If blades are designed to be removable and replaceable, then the ease of repair is improved, but the reliability of the coupling may deteriorate due to repeated assembly and disassembly
Solution Approach 1:
The coupling system is designed with dynamic characteristics that allow controlled assembly and disassembly through the motion weld process. The friction welding mechanism enables blades to be repeatedly attached and detached while maintaining consistent coupling quality, as the process accommodates minor variations in alignment and surface conditions that occur during multiple assembly cycles.
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 enables a robust and reliable coupling of blades to disks through friction welding, allowing for efficient repair and replacement, enhancing the durability and operational efficiency of gas turbine engines by ensuring precise bonding and minimizing material exposure to working fluid leakage.
Implementation Method 1
creating a relative movement between the blade and the disk to weld the blade and disk together
Implementation Method 2
eliminating a material from an integrated turbomachinery component that includes a blade and a disk to remove the blade from the disk
Data Source
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AI summary
In some examples, an apparatus may include a gas turbine engine component comprising a blade, a platform forming an airflow surface from which the blade extends on one side, and a motion weld receiving surface disposed on a non-airflow side of the platform, and a disk having a motion weld disk portion to receive the motion weld receiving surface of the gas turbine engine component and form a motion weld coupling when the disk and gas turbine engine component are coupled, wherein, prior to coupling, the gas turbine engine component further includes a blade stalk disposed on the non-airflow side of the platform and in which is formed the motion weld receiving surface.